This is my design for a encapsulated mini axial flux alternator for tiny wind or water turbines. It's capable of producing >12V when turned by hand. A detailed power analysis has not been done yet, but the design is proven to work quite well. Smaller magnets were used at the beginning but they were not performing that well. The 20x10x2mm N52 ones are much better for that purpose.
A 3D-printable coil former for winding the 6 coils is also provided. It can be attached to a continous rotation servo or a power tool. Attach a mechanical or electrical counter. I've put together a quick and dirty arduino-based counter with a reflective distance sensor as you can see in the pictures. This project was a motivation to build a fully automatic winding machine as well which guides the the wire for you, which was quite a bunch of work. I'll post more details about all that on my blog in the future, I hope you find this alternator useful.
https://www.youtube.com/watch?v=nuLBbzx3v4c&feature=youtu.be
| coil_winder_bottom.STL | 35.8KB | |
| coil_winder_lid.STL | 18.2KB | |
| magnetic_rotor_bigger_magnets.SLDPRT | 467.0KB | |
| magnetic_rotor_bigger_magnets.STL | 35.6KB | |
| Servo_holder_for_winding_machine.STL | 59.5KB | |
| stator_shell_back_rev.2_.SLDPRT | 554.0KB | |
| stator_shell_back_rev.2_.STL | 120.5KB | |
| stator_shell_front_rev.2_.SLDPRT | 298.0KB | |
| stator_shell_front_rev.2_.STL | 120.5KB | |
| stator_shell_rev.2_.SLDPRT | 384.5KB | |
| stator_shell_rev.2_.STL | 151.2KB |
