• Overview
• Materials
• Build
  • Downwind Magnet Disk
    • 1. Sand all surfaces
    • 2. Clean all metal components used in this assembly
    • 3. Prepare Downwind Magnet Disk
    • 4. Prepare the glue
    • 5. Completely moisten the Downwind Magnet Disk with epoxy adhesive
    • 6. Place the Magnet Stencil
    • 7. Place the Magnets
  • Upwind Magnet Disk
    • 1. Sand all surfaces
    • 2. Clean all used components
    • 3. Prepare Upwind Magnet Disk
    • 4. Completely moisten the Downwind Magnet Disk with epoxy adhesive
    • 5. Place the Magnet Stencil
    • 6. Place the Magnets
  • Paint all components

Overview

The Alternator Rotor is the rotating part of our Axial Flux Permanent Magnet Generator (AFPMG). It is a double-sided design with the Stator in the middle. Both discs are identical in the arrangement of the magnets, 12 magnets are glued to each disc in a circular pattern, alternating in polarity. When mounted together, the opposing magnets have reversed polarity to create a magnetic flux. The discs differ in their general design, with the Upwind Magnet Disc providing mounting surfaces and holes for attaching the Blades and Taper Bush. The Taper Bush clamps the shaft orthogonally to the alternator rotor.

Materials

See pos. 2 in the BOM, not all materials listed there may be required at this point.

Build

Downwind Magnet Disk

1. Sand all surfaces

Wherever the adhesive will be used, the metal must first be roughened with sandpaper.

2. Clean all metal components used in this assembly

Use protective gear and acetone for cleaning during this assembly.

3. Prepare Downwind Magnet Disk

Place the Downwind Magnetic Disc on your workbench. Don't forget to put a piece of cardboard or similar underneath to protect your workbench.

4. Prepare the glue

Before mixing the two component epoxy adhesive, check that you have all the components ready for the next steps. After that mix the two component adhesive according to the manufacturer's specifications.

5. Completely moisten the Downwind Magnet Disk with epoxy adhesive

6. Place the Magnet Stencil

To ensure the stencil is perfectly placed, use a few screws to secure it to the Downwind Magnetic Disc before placing the magnets.

7. Place the Magnets

Place the magnets on the disc in alternating polarity. Always check the polarity of the next magnet with the one that has already been glued. To do this, hold the next magnet in your fist and then run your hand carefully over the glued magnet to feel the polarity in your arm. If the magnets repel each other, the magnet in the hand can be placed on the disc in the next free spot.

Upwind Magnet Disk

Repeat the above procedure with the Upwind Magnet Disk.

1. Sand all surfaces

Wherever the adhesive will be used, the metal must first be roughened with sandpaper.

2. Clean all used components

Use acetone for cleaning and protective gear during this assembly.

3. Prepare Upwind Magnet Disk

Use the same process as above.

4. Completely moisten the Downwind Magnet Disk with epoxy adhesive

5. Place the Magnet Stencil

To ensure the stencil is perfectly placed, use a few screws to secure it to the Upwind Magnetic Disc before placing the magnets.

6. Place the Magnets

This time check the position of the first magnet with one of the glued Downwind Magnet Disk for the first magnet you place. As mentioned above, the opposing magnet on the other disc must have the reverse polarity (the magnets attract each other.) to create the desired magnetic flux. Once the first magnet is in place, repeat the process while alternating the polarity like before.

Paint all components

Use the exterior metal paint to paint the two discs, hang them up before painting.