This process will detail how to prototype small axial generators for use in wearable products.
Step 1: Parts List
- Removable Stator Base (http://bit.ly/29NsV7P)
- 9X Removable Stator Pole (http://bit.ly/29NsV7P)
- 37 AWG Copper Wire (http://bit.ly/29NsZ7w)
- Fast Drying Super Glue (http://bit.ly/29DRNuq)
- Milwaukee Tools Stop Lock Hand Clamp (http://bit.ly/29J4nKT)
- 2X Custom Winder Head (http://bit.ly/29NsV7P)
Step 2: Assembling the Stator Winder Clamp
Remove the standard headers on the Stop Lock Hand Clamp and replace with the Custom Winder Heads to create the Stator Winder Clamp.
Step 3: Clamp the Pole
Clamp the Removable Stator Pole into place with the Stator Winder Clamp. Ensure that the Removable Pole is seated in the pockets of the Custom Winder Heads.
Step 4: Fix Clamp to Table
Clamp the Stator Winder Clamp with the clamped Removable Stator Pole to a surface so that the end is overhanging for easier winding.
Step 5: Wind Pole
Begin winding the pole by passing a spool of wire around the pole and through the overhanging opening. Before winding, strand out about 2 inches of wire lead for easier soldering in later assembly steps.
Notice how the wire is wrapped around a bolt for easier handling.
Keep wire tight for 400 winds.
Step 6: Remove Wound Pole From Clamp
Strand out a couple inches of wire after winding and cut the wire. Open the clamp. If the wire is tightly wound, the wrapped pole will hold shape and drop out of the headers.
Step 7: Place Pole
Place the wound pole onto the Removable Stator Base, lining up the poles with one of the open holes on the base. Be sure to make note of the direction of the winding - CW or CCW, as this will need to be consistent for all poles.
Step 8: Set Pole
Add a small amount of Fast Drying Super Glue to the bottom of the base at the opening with the pole in place to secure it. Once the glue has dried, add a small amount of glue to the top of the winds to keep them in place.
Step 9: Repeat for Remaining Poles
Continue winding and placing poles until all nine are in place. Again, ensure that all winds are wrapped in the same direction.
Step 10: Solder Wires
Solder the individually wound poles according to the diagram shown in the photo.
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