Three Phase Generator

Wait! Its for today?!

This is the question I woke up with this morning. I sprinted out of bed to confirm my worries. Hurriedly, I set a 23 hour timer and began to work. I had been wanting to make a generator for a very long time, this projects last minute pressure was the perfect push into starting it, and the idea of building a generator in a day seemed like the perfect challenge. 

Nothing could have prepared me for the following hours where a walk to the hardware store would end up in the persecution of my neighbors escaped dog, spending more than half an hour trying to separate the magnets(can’t believe it took that long!) or my printers super convenient warning of abnormal bed leveling behavior ( I still don’t know what that means). However, after much effort and many setbacks, I managed to build a three phase generator. 

• magnets ( take into account strength) https://amzn.eu/d/2hjGK0e 
• enameled copper https://amzn.eu/d/9qHPUnG or thin wire
• Nuts 
• Metal rods (5 x 200 millimeters) (hardware store)
• 3d printer
• glue for plastic (hardware store)
• calipers for precise measuring

First, I had to understand what a generator truly was and how it worked. Essentially, a generator consists of a magnet and a coil which move and interact with each other. 

In this case, electricity is generated thanks to the constant movement of two magnets, which act together as one. It works by creating a change in the magnetic field of the coil. The change in the magnetic field induces a voltage which then leads to the flow of electric current.

Remember there are many types of generators and you should choose the one that fits your needs better. I choose to do a three phase generator. This types of generator is commonly used because, as shown in the diagram below, there is more than one coil and the power is produced more efficiently and balanced.

In this project time was my most valuable resource and it was vanishing rapidly, I had only one chance to succeed. If there where faults in the design, there wasn’t going to be enough time to reprint the generator. So, I sat in front of my computer and set rules for my design: 

• it should print efficiently and fast (in case of any mistakes)
• Parts should be assembled without any trouble

Having the rules clear, the designing process began. I divided the generator into two parts: the magnets; this included all the parts that needed to be in motion, and the coil; this was the static part of the design. 

For the magnets I designed a container, shown in the images below, where a rod would go through the middle and rest between two “columns” with supports. The rod has attached a printed handle, which allows me to generate the motion.

For the coil, I designed a hexagon-like structure. Using a design similar to the one of a picture frame but instead of a 45 degree angle cut, a 60 degree angle cut. I then printed six mushroom-shaped figures to stick to each of the frames. In this shapes I will wind the enameled copper. 

The assembly was fairly simple since my design was intuitive. I started with the magnets. Without the use of glue, both magnets stuck together perfectly. Notice that the pole orientation is insignificant since the current is alternate. I then placed the metal rode and tightened it in place with some nuts. 

The second part I assembled was the frames. I glued the mushroom-shaped figures onto the middle of the frames. Then winded the coil as shown in the diagram below. Keep in mind, this process requires patience and organization and might not come out in the first try. You might have to re-do the winding.

After having glued all the frames together, you can finish placing the frame with the magnets ( as shown). The hexagonal frame comes without a column to support it since I didn’t have enough time to print it. Instead, you can use some books or whatever is near you to create the support with the perfect height. 

The next thing you have to do is place the final column. For more stability, you can tighten the columns in place with some nuts and glue the supports into the columns. Although, sticking them is optional since the supports fit perfectly into the columns. Finally, I assembled the handle and again tightened it in place with some nuts. 

If any of the parts don’t fit perfectly, I advise you use sandpaper to adjust them to the required size.

Now its time to connect the generator to fit its purpose which can vary depending on the use you want to give it. 

The 24 hours are coming to an end. I'm afraid I couldn't get to assemble the generator in its entirety due to a fault in the size of the frames. Here in Spain, its 7:54 in the morning and there are 6 minutes until the deadline, so, I decided to submit the project anyway. I had great fun and I will finish this project individually. It's a pity I won't get to show the results in this intructable! Thank you for your time.