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So I unwound the stator this morning.. I had nothing to do cuz I'm always up early... I found that there was a big discrepancy in the amount of windings per post/tree (whatever you want to call them)... Anyways what I did find was the most common windings was 26 per post (8).. 6 posts had 25, 1 post had 28 and 3 posts had 27... By the way I understand this, inequality creates dirty power which can affect your system.. Now keep in mind this is an OEM Harley stator. Other things I found were that in a lot of areas there was hardly any coating on the wire at all.. You can see that in the pictures as well.. I highly doubt these were made in the USA, probably some more China crap.. So anyways it appears that each length per phase was 40 ft.. I just got to make sure I get the right size wire and temperature range. You can also see in another picture where there was huge gaps in the windings.. I'm sure that this would also affect the cleanliness of the voltage.. I don't see any reason why I can't do a better job than what was purchased.. we'll see... I have a couple cycle electric stators, I just might unwind those to see what kind of quality difference there really is.. Who knows we'll see..
Question: Is it better to have an even number or odd number of windings per post? Keep in mind I will make sure that all posts are equally wound..
This poorly insulated spot was very common throughout the windings..
I know it's hard to speculate but with all this info, I wonder how long this stator would have lasted... And is this common.. I would've expected a little more consistency .
I would guess the insulation peels off after the straightening. I would also assume they purposely put the winding count the way they did for a reason. I would do it exactly how they had it.
how much is a roll of wire?
chinesium is what they are including the regulator, hd goes cheap and engineered just to work. also, this is done via a machine. what i did find interesting is that the winding count was off that much. however, i do not think it will make that much diff since it will be an average of the phase. each phase should have near the same ohms and coil count so that the magnetic saturation is close. since it is a pmg, you will have some hash but it is very minor, occurs when the magnetic fields hand-off.
the varnish is very tough, i have to heat the end and then abrade till it is shiny.
yes, scattered wind does effect electrical output but in a power application no way near like a guitar pickup which alters tone which some say is a good thing. i would not worry about it. i have done series forms and the the diff you saw was not there. i see you got the wye setup and it will give you more amps than delta.
GREAT JOB!!!
Update: Spoke with the Techs here at the lab and with their suggestion I went with a Remington's Industries 16AWG coated spool good to 200 degrees Celsius. Should do the job without issue. At 28 winds per post or even 30 it won't affect the out put of the a/c field.. Ordered it on Amazon and should get it in a week.. Should be a good winter project...
Update: Spoke with the Techs here at the lab and with their suggestion I went with a Remington's Industries 16AWG coated spool good to 200 degrees Celsius. Should do the job without issue. At 28 winds per post or even 30 it won't affect the out put of the a/c field.. Ordered it on Amazon and should get it in a week.. Should be a good winter project...
Too cool. You need to put this on Youtube. I can find no post there. I also cannot find a machine that can wind it. I think it's done by hand.
Too cool. You need to put this on Youtube. I can find no post there. I also cannot find a machine that can wind it. I think it's done by hand.
I'll I'll probably make some time-lapse videos and post them all together at once It's going to be a long process cuz yeah I do have to do it by hand.. either that or I take it to a generator shop and have them do it but that defeats my whole purpose of wanting to learn something here..
I'll I'll probably make some time-lapse videos and post them all together at once It's going to be a long process cuz yeah I do have to do it by hand.. either that or I take it to a generator shop and have them do it but that defeats my whole purpose of wanting to learn something here..
In the 60, I had a 62 Convair Convertible Spider with turbo. Had a generator on it. I carried it to a generator shop. They turned the commentator for me.
I bet you carry that to a shop today, they would charge you $300 or more plus material cost. Unless you are in India. Those boys rebuild China $30 ceiling fans.
Definitely not as easy as it looks and the .053" wire that I used wasn't to difficult to wind but was tiresome.. Also a couple pics, one of the first phase done and then one of the resistance reading .2 ohm's..
I will post more as I complete the windings.. I don't think that the 125' roll of magnet wire is going to be enough. Each post requires almost 8' of wire.
Well I finished out the coil of wire and unfortunately I ended up four feet short The very last post is only wound once to the top Didn't have enough wire to bring it back down... So to complete it I'm going to have to get another spool of wire and pull off what I have on that one phase and redo it... What a drag... The short post is phase one end 1E.. The pen is pointing to it.. My connections are as follows. 1 start to 3 end, 3 start to 2 end and 2 start to 1 end.. As in the diagram I drew up.. I'll keep updating as I go time to order new wire...
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