Rotary Pulse Voltage Frequency Generator Assembly

[Login to see usernames]

I see your drawing is okay.
Like SI 10 alternator 42 slot 14 coils per phase.
The little red line drawing underneath is showing correct.
The 2 leads will finish 3 slots from each other and this is all good.

[Login to see usernames]

Thanks,komtek,the pic is from the web a random one,not my real stator,mine is much smaller,12cm OD,36slots,12coils.You said the leads of windings are 3coils apart,can you edit my photo and draw a few lines?the leads of the phases are decalated between them (for ex.in my pic,my blue phase start in the next slot after the start of the red phase)so the blue phase should start after 3 slots?or the leads are simply draged trough to be 3 coils apart?see att.

[Login to see usernames]

Got mine ready, dipped and baked twice.
Fits good in housing.

When you are ready and have made your coils, then install them just as planned.
UP/OVER, DOWN UNDER until the end it should be much more easier than talking about it and drawing it out.
Install one whole coil, then the next in the next slot over and then the third beside that one.
First coil side goes in, miss 2 spaces then other side of coil, then next coil loop over that one.
One phase coil complete before you do the next coil set.

[Login to see usernames]

Very nice,how did you manage to fit 20turns per coil in that tight space?how much turns was factory?
Komtek believe me i rewound my stator 3 times,and did not output much(6v),many hours and nerves,winding each coil on a ''sandwich'' former,diasemble fix the coil beter,some 6 hours per phase,and another 2 for sliding them in that 2mm space,ruined wire from scratching etc...and in the end 6v..and thats why i'm bugging you with so much question and drawings,to not repeat the process and ruin so much wire.The drawing i made was how i wound mine and did not work,so your doing something something diferent...

[Login to see usernames]

Hi Adys

So how much volts and amps do you put on the rotor?
Maybe there is your problem?

[Login to see usernames]

I used a pc-powersuply(5v-0.8A-at the rotor).This is not the problem,with a stock stator was producing 30v,with my stator only 6v.

[Login to see usernames]

Very nice,how did you manage to fit 20turns per coil in that tight space?how much turns was factory?
Komtek believe me i rewound my stator 3 times,and did not output much(6v),many hours and nerves,winding each coil on a ''sandwich'' former,diasemble fix the coil beter,some 6 hours per phase,and another 2 for sliding them in that 2mm space,ruined wire from scratching etc...and in the end 6v..and thats why i'm bugging you with so much question and drawings,to not repeat the process and ruin so much wire.The drawing i made was how i wound mine and did not work,so your doing something something diferent...

Factory on the few I took apart were always around 4 turns per coil #12 wire or 8 wires per slot.
If the wires were real scratched and shorted turn to turn this will effect your output.
If a wire got on the outside of the slot liner this will effect your output.
If a wire was possibly touching the metal housing, this is not good.
When wire is inserted in each slot it is done with much care, not to force any wire.
In your fingertips you flatten the wire coil so it slides right into the slot.
Actually many times I have flattened adjusted the wire and it goes into slot with one motion only.

You maybe can wait until I set up a test and we can see if my alternator works.

[Login to see usernames]

The wire was not scrached when inserted(flatening the coil sides like you said),but when i get it out its a mess.The coils were not shorted,i measured the impedance,off and on the core,not touching the stator core either,i verified it.
The only thing i dont understand is the leads position on the stator,i think thats where my problem is.its something to do with electrical degrees...
2mm wire on a stock one,8t per coil,thats plenty of space to play with.mine had 5t 18gauge...
I dont say yours will not work,just that you'v done something with thouse lead coils positions on the stator...cheers