Radial Air core alternator Fun!

These are simple radial air core alternators that anyone with a drill and jig saw can build.
Below are the basic parts for a single magnet 3 phase alternator...
2 plastic triangles sied to match the width of the magnet your using! " magnet! some
small wooden dowl! 2 "#$% round steel stoc& ' cut bolts wor& well (! and some "#$% bar
stoc& that closely matches the thic&ness and width of the magnet your using. Also! some
copper magnet wire for the coils. Below shows the basic frame assembled...
)e*t you+ll wind 3 coils that will fit around the frame...
, used "-- turns of .2/ wire as an e*periment and it wor&ed pretty well but you can
adjust the amount of turns you want based on the 0oltage you need. The more turns!
the higher the 0oltage but lower amps. Basically ta&e all the end wires and connect them
together and use the remaining 3 wires as the output.
1ay the 3 coils o0er the triangles and tape the coils together. ,t+s wired just li&e a
standard 3 phase winding in star ' for higher 0oltage(. Below is the unit completed.
2ome small plastic spacers were added as stand off+s for the base and , simply used
wood screws to hold it in place. 3reat for a mini wind turbine !
Below is a picture of the completed unit...
,t easily lights 145+s as well has the ability to charge nicad batteries... gi0e it a spin !
6ant more7 8&! how about a $ pole radial air core. This one ta&es a bit of patience and
a bit higher s&ill le0el but ma&es a nice 2-9:-; watt alternator ...
<ere is a shot of the parts you+ll need to ma&e...
The drilled plastic end plates! $ wooden dowls! $ magnets! a solid s=uare steel magnet
mounting bloc& ' , used a " * " inch s=uare steel solid bloc& to match the width and
length of the magnets (! a "#$% shaft and 2 9 "#$% bearings.
The layout and drilling is easy if you ma&e a pattern and tape it to the plastic. Below
shows the layout sheet... The large wire holes are "#2 inch which isn+t stated on the
drawing.
As with the smaller one the assembly is =uite simple. 5rill through the center of the
s=uare bloc& and glue the shaft in place with >bweld . 3lue the magnets to the s=uare
bloc& ' )929)92(! And your assembly should loo& li&e the one below..
This one you wind the coils in place one at a time. ,ts wound li&e a single phase
alternator and each phase shares the slot with the ne*t coil. The coils are wound to
match the magnetic poles ' cloc& wise! countercloc&wise! cloc&wise and counter
cloc&wise for each phase (. 2tart winding in one slot! s&ip 2 slots and complete the turn
in the 3rd opening. , used .2- wire in the one , did using $- turns per coil. The second
and third phase goes in just li&e the first. ,t ma&es it easier if you ha0e 2 9 "#2% dowls to
wind the wire around and to remember to s&ip those slots. Below shows the $ pole
alternator completed...
For mounting! you could wrap the outside of the unit in a thin ?@A plastic sheet or cut a
pipe to fit. 2ome stainless hose clamps to hold and mount it ! Bou can also alter the
parts to ma&e it a bit hea0ier duty! such as replacing the "#$% shaft and bearings with a
"#2% shaft and bearings.
6iring it is the same! Tie the 3 end wires together for star and the remaining 3 are your
output wires... <a0e Fun!

Car& your start wires and end wires for each phase to ma&e it easy to distinguish them
when its completed.