PARTS LIST AND CONSTRUCTION DETAILS

When building your first unit we suggest using the stated materials.
1) Aluminum Base Plate
 

2) Sleeve Bearing, 1" long, ½" inside diameter, oil impregnated brass.
 

3) 4" long by ½" diameter Brass Shaft
 

4) Brass 2" diameter Rotor, 1—3/4" long
 

5) Six rotor slots, each 1—3/4" long by .260 deep by 23/32" wide. These slots are spaced exactly 60 degrees apart.
 

6) One slot cut in center of Brass Rotor, 360 degrees around, ¼" wide by 5/16" deep.
 

7) 12 slots (formed from the six slots as the 360 degree cut is made). Each slot is lined with .010 thick mica insulation.
 

8) A total of 228 pieces of U—shaped .040 thick copper coated steel wires. Each slot (Part #7) has
19 pieces of these wires fitted into the Mica, thus these wires do not contact the Brass rotor. The
lead edge of these wires (See Figure 7) is flush with the Rotor’s outer surface and the trail edge
protrudes 1/8" above the Rotor’s outer diameter.
 

9) Eleven complete turns of .032 thick copper coated steel wire. These 11 turns or ‘wraps’
accumulate to 3/8" wide and the same pattern is placed around all 12 magnets. When placed into
the bent wires #8, they are a snug fit making firm contact.
 

10) Are 12 pieces of .005" thick mylar insulation inserted into the cores of the wires #9.
 

11) 12 permanent magnets, insulated with the mylar, to not contact wires # 9. These magnets
measure 3/4" long, 5/8" wide, 3/8" thick and are made of a special composition and strength.
Alnico 4, M—60; 12 AL, 28 Ni, 5 Co, bal Fe, Isotropic permanent magnet material cooled in
magnetic field, Cast 9100 TS. 450 Brin, 2.2 Peak energy product. When inserted in the rotor the
outer faces of these 12 magnets are not to be machined to a radius. The center of these magnets
pass the center of the coils with 3/32" clearance. The edges, where the wires are wrapped, pass
1/32" away from the coils. This ‘changing magnet spacing’ aids in not only the release cycle but also
contributes to rotational movement. (Sharp magnet edges which are facing the coils are to be sanded
to a small smooth radius.) 51
 

12) Magnet polarity placement into Rotor. (See Figure 5.)
 

13) Connection pattern for wires wrapped around magnets. (See Figure 6.) The 12 wire wraps are
divided into two sections, upper and lower of six each. There are no connections between these
sections. The magnetic flow direction between the upper 6 wraps and the lower 6 wraps is attained
by the ‘flow direction’ as shown in Figure 5. Viewing Figure 6 shows the wires wrapped around the
magnet starting at the top ‘north’ half and then after 11 complete turns the wire exits at the lower
‘south’ half. As this wire then goes to the next magnet it arrives at an attract wire which is its ‘north’
side. Thus all wires get interconnected from south to north magnet half or north to south magnet
half. The actual connections should be crimped copper clips not solder with insulation tubing to
prevent contact to the Rotor body.
 

14) A .030 thick copper tube (stiff material) 2" long by 2½" inside diameter.
 

15) Are six slots cut at the top of tube #14. These slots are 5/8" wide by 1/32" deep spaced at 60 degrees apart.
 

16) Are six slots cut at the bottom of tube #14. These slots are 5/8" wide by 5/16" deep and in line with the upper slots #15.
 

17) Six copper tube mounting points.
 

18) Acrylic ring to hold Part #14, measuring 3—3/4" O.D., 2¼" I.D., 3/8" thick bolted directly to
Part #1. This ring has a .030 wide groove cut ¼"deep to allow the six copper tube mounting points, Part #17, to be inserted.
 

19) A .002" thick plastic insulation paper to be placed around the inside and outside of Part #14.
 

20) Are six coils of insulated copper wire, each coil having 72 turns of .014 thick wire. Each coil is
wound with two layers, the bottom layer to completely fill the 5/8" wide slot with 45 turns and the
top layer to span 5/16" wide with 27 turns. To be sure each coil has the exact wire length or 72
turns, a sample length wire is wrapped then unwound to serve as a template for six lengths. A
suggested coil winding method is to fill a small spool with one length then by holding the copper
tube at the lower extension, then start at the plus wire in Figure 2 and temporarily secure this wire to
the outer surface of the tube. Next, place the pre—measured spool of wire inside the tube, wrapping
down and around the outside advancing clockwise until the 5/8" slot is filled with 45 turns. Then,
return this wire back across the top of the coil for 15/32" and winding in the same direction again
advance clock—wise placing the second layer spanned for 5/16" with 27 turns. This method should
have the second layer perfectly centered above the first layer. After winding this coil, repeat the
process by again filling the small spool with another length of pre—measured wire. A very
important magnetic response happens as all six coils have their second layers spaced as disclosed.
 

21) This number identifies the top view of the second layer.
 

22) Connection pattern for six coils shown in Figure 2. When the unit is driven at start—up (hand
crank) for 42 seconds at 2100 RPM, all six jumper wires must be together which means the plus wire
goes to the minus wire connected by the start switch. After 42 seconds the load is added to the
circuit and the start switch is opened. To double check your connections between the coils, note that
the finish wire of coil #1 goes to the finish wire of coil #2, which is top layer to top layer. This
pattern then has start of coil 2 (bottom layer) going to start of coil 3 (also bottom layer). When the
copper tube with the coils is placed around the rotor, the distance from any magnet to any coil must
be identical. If it measures different, acrylic holding shapes can be bolted to the aluminum base,
protruding upward, and thus push the copper tube in the direction needed to maintain the spacing as stated.
 

23) Wires to load.
 

24) Wires to start switch.
 

25) Rotational direction which is clock—wise when viewing from top down.52
 

26) Acrylic dome for protection against elements.
 

27) Coating of clear acrylic to solidify rotor. Do not use standard motor varnish. Pre-heat the rotor
and then dip it into heated liquid acrylic. After removal from dip tank, hand rotate until the acrylic
hardens, then balance rotor. For balancing procedure, either add brass weights or remove brass as
needed by drilling small holes into rotor on its heavy side.
 

28) Insulation tubing on all connections.
 

29) Shaft for start purposes and speed testing (if desired).
This concludes the parts list for the Mini—Romag.