3rd Prortotype

The third prototype is developed with the objective to increase the current output. We had several discussions with Mr. Prabhat to evaluate out prototype output performance, as well as how to increase the current output. We took the advice to include an iron core in the generator. We decided to wrap the coil windings with the iron plate on the outer side, as shown in following figure.

We had also reduced the air gap by increasing the permanent magnet diameter. The magnetic strip was placed on the permanent magnet outer diameter, as shown on figure above. The improvement on third prototype has resulted a load on the rotor (magnet). Now, it required force to move the rotor up and down.

Again, the similar tests were carried out. With this prototype, we manage to charge up the capacitor faster and higher voltage. Result as the following figure.

We are satisfied with the current performance of the generator, and we believed the output will be sufficient for the generator to be installed and tested on vehicle.

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2nd Prototype

Since the first prototype does not produce sufficient output for testing, we have decided to improved the prototype design. For the second prototype, we have double up the number of coil windings (N) from 300 to 600. Then the prototype was tested for the output voltage. Following figure shows the result from the second prototype.

The second prototype has shows a significant improvement in term of maximum voltage. It produced a maximum voltage up to 2.168 V. However, the current output remains same as the first prototype. The generator then tested to charge the 3900μF capacitor. Following figure shows the charge voltage on capacitor at same frequency as it was tested on the first prototype.

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Generator Prototype

The main component in the project is the generator. At this stage, the first prototype was built to generate voltage and current for the system. The main material involved in this prototype are;
         1.   0.25mm (d) of enameled copper wire
         2.   40mm (d) x 10mm (h) Neodymium magnet
         3.   50mm (id) x 80mm (h) pvc tube
         4.   Single phase 1.0 amp Bridge Rectifiers.

In this first prototype we have the coil wounded for 300 turn (N). Both end of the copper wire were connected to the bridge rectifier. The (+) and (-) output terminal of the rectifier is connected with the wire to use as a probe for test.

The first bench test was conducted on 31 November 2011. The computer oscilloscope was used to capture the peak voltage from the generator. At this stage, the induced magnetic field generates small voltage were detected. Figure below shows the peak voltage generated by the generator (0.962v).

From the test result, we agreed that the peak voltage and current generated are too small for the project objective. We need to improve the generator design in some areas in order to amplify the output.