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Gen6 - 3d printed, Halbach Array electric power generator

by TanyaAkinora Nov 9, 2017
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Sorry I need to ask again, but the output power is totally weak. I tried different loads and was able to get only 0,07W at approx 250-300 RPM. (turned by hand)

Voltage is not a problem, it rises up to 10V at this low speed, but nearly no current. My plan was to use this generator to charge a lead acid battery bit it will take decades with this low output.

Maybe I connected the coils wrong? I build two groups of coils, one group consists of the four inner coils, one consists of the four outer coils. I connected the four coils of each group in series resulting in four wires coming out of generator. Each group has a resistance of 56 Ohm, which seems to be very high. Each group is connected to a rectifier and the output gets stabilized by a large capacitor.

Behind the capacitors, both groups are connected in parallel.

How can I increase the power output? Is it better to connect the coils in a different way? For example, should I connect the four coils of the groups in parallel, or two in series and two in parallel?

Hi, Patrick
Gen6 was developed to work in a wind turbine and for a large range of wind speeds. Therefore, a model without an iron stator was chosen.
In your case, you can increase power by following a few points:

  1. Connect the windings in parallel as you described. This will lower the voltage, but increase the current and decrease the total resistance.
  2. Surround the generator stator with a ferromagnetic cylinder. This will not affect the cogging of the rotor but will improve the shape of the magnetic field.
  3. Apply a diode bridge with Schottky diodes.
  4. Do not load the generator on the battery directly, only with a current stabilizer and even better MPPT converter.
    I am glad to answer all of your questions.
Comments deleted.

Any hints about winding the coils? I've read at some place that you use 800 windings each coil using 0.2mm wire. Because someone note, that 800 did not find and he uses 650 instead, I tried with 700 as starting point. I build one coil and tried to put cover over it. This was impossible. Next I tried with 600, but again, it did not fit. Last try was with 500, but it will not fit all 8 together.

So in my opinion, 400 would fit. Any ideas how much power I get out of this with 400 windings?

How many windings did you use?

The number of turns determines how many volts you will get from the winding. You can easily compensate for the lack of voltage by increasing the number of revolutions of the shaft. By this 400 turns is good.

Hi :-)
I love the design. I am trying to find the bearings, but could not find any of type "625SZ (16x5x5mm)". I found some with "625-ZZ 5x16x5mm" (https://www.banggood.com/10pcs-5x16x5mm-Shielded-Miniature-Metal-Sealed-Ball-Bearing-625-ZZ-p-82048.html). Are they the same or compatible?

Yes, you can use these bearings.
Thanks for the comment.

Ever get specifications on output? I was reading and didn't see any

Татьяна, Здравствуйте. Решил использовать ваш генератор для вертикальной ветротурбины(https://www.thingiverse.com/thing:1718731). Столкнулся с некоторыми сложностями:
1) Так и не понял сколько витков провода надо сделать на 1й катушке.(у меня получается 300 витков 0,2мм до размера как на фотографии)
2) Можете написать наименование диодов для мостов?(или дать ссылку на али)
Большое спасибо за такой интересный проект)

Vertical Wind Turbine VAWT

Здравствуйте, Антон. Спасибо за отзыв.

  1. 300 витков достаточно, можно и меньше. Важно, что бы их было одинаковое число на всех катушках.
  2. Диоды любые на силу тока более 1А. Рекомендую диоды Шоттки, например 1N5817, 31DQ10, SB140.
    Спрашивайте, если нужно и делитесь результатами!

Татьяна, спасибо за советы! собрал генератор, но почему-то работает только одна фаза. Сопротивление у фаз прозвонил- одинаковое. Может я неправильно соединил фазы? Я объединил начала 2х фаз, а концы вывел на диоды. одна работает, а вторая нет.

Первым делом проверьте правильность соединения катушек в каждой фазе. Затем проверяйте переменный ток в каждой фазе при раскрутке пальцами. После этого ставите диодные мосты.

Hello Tanya,

My son and I like your desing very much and want to use it for a school project. I find almost everthing on your page and here but I have one question: do you have a electric connection diagram for the coils?


Look at the circuit of the inductor for Elveet. https://www.instructables.com/id/Elveet-Kinetic-Charger-Poverbank/
It is suitable for the generator Gen6.
Good luck in the project!

Were did you find coils?

Hi Tanya,
Love your design !! looks great !! I have been reading all the comments, and I'm wondering if you had time testing it ? how much power is it generating ?
Also, looking into making a small windmill, I was wondering if you posted anything (file or tutorial) about your design of a axial generator.
Rotor 160mm, 60 magnets 25X5X5 or 120 pieces 25X5X2.5mm

Thank you!
After the holidays, I will try to publish the test results.
As for the second generator, I would love to write a guide, but I'm afraid that the level of my English is not enough for such a job.

Hi Tanya,
did you find some time to assess the output characteristics of your generator in the meantime?


If that is the problem, no worry, google translate works fine ! I read your tutorial on 3dtoday.ru ^^
keep posting your design, along with some explanation, they are just great stuff -> thanks

hi tanya power full project .I will try .thanks

Interesting but very time consuming project. What makes it better than simply using stepper motor or some other market motor to generate same power?

To do or not to do, that's the question!
I already said that the stepper motor as a generator is a bad idea. For many reasons, I do not recommend doing this. But the choice is yours.

I don’t need generator :), but what I meant is: there are very cheap factory made generators available all over the market. What advantage does this design offers, considering the time involved in making this. It is awesome as educatonal project, no doubt. But is there any real use value to it?

It is more fun to make something that simply buy it,

Yes, totally agree. But I like to make things that are worth the time in the end of a day and do not cost 100 times more in labor and time to make them than better factory versions on a market. I totally see this as educational project though.

Cheap generators available on the market are not efficient and the more expensive (> 100$) are not suited for small projects (like a small windmill).
3D printed ones are scalable :)

I agree. You should learn many things.

What direction are the magnets charged? What direction is North and South? I see the lines in your photo so I am assuming it is through the thickness and not along the length. Please confirm. Where did you buy the magnets? Inigo did not appear to have these. Also, I want to charge batteries with this. What is the voltage it produces? How do you recommend connecting the coils? All in parallel? What about the phase? I am very excited to make this and should be fun to use. Any suggestions on what wind turbine to use it on? Thanks for all your great work!

I drew the location of the poles and their direction.
You can connect the coils in series and in parallel, but only in pairs. That is, all yellow and all red as in the picture. You will have 4 output wires. Next, you connect two diode bridges and after them connect the phases of the generator together.
I bought magnets from a local vendor, 1 dollar for 1 piece.
The test results will be later. To begin with, I recommend the rotor Ugrynsky, which I previously published.

Thanks for the quick reply. Everything is clear. We don't have metric here in the USA if you haven't heard...I am lazy and didn't redesign your 3D model so I ordered my magnets from China. No dollar store with metric magnets here. Now I just need to wait for them to arrive. I have seen your rotor as well so I will start with that. It has been a long time since I've wound coils and I have my winding motor set up but it is thrown together and needs a turn counter. Thanks again!

Very very nice design. Well done!

Any info on output vs RPM already?

Work in progress.

is this design scalable?

Yes. But for every other application, I recommend calculating another generator. The principle of operation can be applied to radial and axial generators.

Can't wait to make this!. What is the wrap you are using to wrap the coils?

Usual Teflon tape.

I'm really interested in seeing how many Watts this can produce at low speed :-)
I'm building a small Wind Generator and I'm still searching for a good power generator to produce a usable current at 60rpm.

Thanks for sharing your design with us !

I'm testing now. But if I saw your wind generator, then I could advise the solution.

Thanks for your reply Tanya :-)
I'm finishing this model : https://www.thingiverse.com/thing:2284021
It's 60cm tall and can start spinning at no load from a low windspeed :-)

Project Aeolus: Vertical Axis Wind Turbine

I would advise you to build an axial generator 120 - 150 mm in diameter. On the same principles. Unfortunately, I now do not have the opportunity to make such a generator. If you decide to make such a generator, then I can give you the necessary consultation.

Hi Tanya,

I have read some articles about the Axial Flux generators and while it's interesting, I won't be able to make the iron cores.
I didn't find either a way to make a coreless axial flux design, it requires magnets that are magnetized in an unusual way which pull the cost of the generator up.
So I'm back to this design of a coreless radial flux generator...
Did you already make any tests of the power it can deliver ?

Thanks :-)

A little patience. Soon I will draw a drawing of an axial generator for your case. Tests are in progress

Oh ! Great, I wasn't expecting that much, thanks a lot !

This is a draft version of the axial generator.
Rotor 160mm, 60 magnets 25X5X5 or 120 pieces 25X5X2.5mm, like these:
The stator is 2-phase, the design of the coils is clear from the figure.
I hope this helps you.

Thanks Tanya ! I will make a design with your drawing and test it !
25x5x5 magnets are not cheap, 20x5x5 or 30x5x5 are and are easier to find but they are rated N52, do you think using one of these would be ok ?

Hi Thomas!
I also do an axial generator.
Let's compete who is faster? :)

I wish but I don't have the hardware... I will first test a Nema motor as a generator to my Wind Turbine then maybe try making an axial generator if it worth it :-)
I'm very curious what power you can get from this generator !

NEMA as a generator is a bad idea. But you decide!

It's not the best solution but I have one Nema 23 lying around and it can help my getting results quickly while working on a generator powerful enough for my needs :)
As a side note, the author of this HAWT tried to make his own generator but didn't get enough power from it : https://www.thingiverse.com/thing:2060281
Maybe he can improve his design for its next iteration ?

Anyway I keep an eye on your project and will not wait too long before trying to make a generator, just for science sake and because you gave me some of your time ;-)

MKII 5 Watt 3d printable Wind Turbine

30x5x5 will be fine.

Comments deleted.

Thanks, 3d designing it and building it would not be a problem, the most difficult part for me would be to know which magnets to use, how many and what coils to use. If you have ways to calculate these parameters, I could make and share a good axial-flux design :-)
At the moment I didn't found any useful ones (they use round magnets, produce a low amount of energy or require higher speed to produce 12V).
Any help would be highly appreciated ;-)

Your tutorial on 3d Today doesn't say how many turns of 0.2mm you did??

Thank you for the question. I wound about 800 turns of wire.

Hello Tatyana. Thank you for sharing your design.
How did you wind the coils? Do you have any pictures of the coils without the isolating tape?

This Monday I will make and publish a complete description of the winding process of the coils.

How much energy/force is required to begin generating electricity? I'm thinking of putting a small turbine in line with the return water flow from a hydroponic system to recapture some of the energy used in elevating the water to the storage tank.

You can use the generator in your design. This generator has no cogging, unlike generators with iron in the coils.

What are the output voltage and amperage? And it's the AC, right? What are it's advantages over conventional generator? What are building details (wire used etc)?

What do you mean when talking about a conventional generator?
The voltage and amperage depend heavily on the rpm. I will publish the exact specifications later.
The wire parameters are listed in the description.

The other day I will publish a full description on 3d today.

Can you give a link to the full description?