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Rotor Winding Tooling

Discussion in 'The Garage' started by Jim, Jul 22, 2018.

  1. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    Yeah... that's closer than I would have guessed, but it makes sense. The closer the magnetic field is to the stators iron cores, the more electricity is generated.
     
    FB71, TwoManyXS1Bs, Superjet and 4 others like this.
  2. MaxPete

    MaxPete New knee installed but still breakin’ her in.... Top Contributor XS650.com Supporter

    Yup, I think is a relationship of the inverse squared type: 1/(gap)**2.

    So, if the gap is cut in half, the flux (which determines the current) is four times as much ( 1/0.5 x 1/0.5 = 4 ).

    So - having a smaller gap is really important to alternator system performance.
     
    FB71, Mailman, TwoManyXS1Bs and 2 others like this.
  3. TwoManyXS1Bs

    TwoManyXS1Bs BBQ Hunter Top Contributor

    Jim, here's a trick.
    XS1B-RearDrum04.jpg

    From here.
    Post #19
    http://www.xs650.com/threads/650-rear-drum-brake-plates.51046/#post-582480

    Pretty close in there. Like a blender.

    Imagine.
    Coupla attachments, a spout,

    and you could make fruit smoothies while camping...
     
    Paul Sutton, GLJ, gggGary and 2 others like this.
  4. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    450 turns of 22ga. copper......

    IMG_20190301_181345.jpg

    Weighs just over a half a pound.

    IMG_20190301_183529.jpg

    Mass production....


    IMG_20190301_202827.jpg
     
    FB71, MrBultaco, 59Tebo and 6 others like this.
  5. MaxPete

    MaxPete New knee installed but still breakin’ her in.... Top Contributor XS650.com Supporter

    Very tidy Jim!
     
    Signal and Jim like this.
  6. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    Thanks Pete!
     
  7. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    So... I freely admit I ain't the sharpest knife in the drawer.... but I do learn. :whistle:
    If you want a rewound rotor to run true, ya gotta start with one that runs true.

     
  8. Mailman

    Mailman Hardly a Guru Top Contributor

    Very nice! There you go thinking like an machinist again! :thumbsup:
     
  9. kshansen

    kshansen XS650 Junkie Top Contributor

    593
    1,281
    143
    Reading this about rebuilding the rotor jogged my memory and got me thinking about problem I had with either a RD200 or was it the RD400?

    Any how it was having a charging problem and I opened up the side of the engine to find that the slip ring plate had come loose on the rotor and actually was cracked in a couple places, wires were still intact.

    Not knowing any better I managed to dig out the epoxy that covered the attaching screws . Seem to recall the screw hole threads were buggered up in the rotor so I tapped them out for machine screw sizes. Then I mixed up some epoxy and worked it in the cracks in the slip ring backer and down between the rotor and the backer and then installed new screws.

    After epoxy set up over night I managed to chuck it up in the lathe at work clamping on the out side of the rotor and took a light cut to true up the slip rings. To my surprise it actually worked when I was done!
     
  10. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    .... and even more tooling.
    To balance the rotor after rewinding, I'm using the drill press. I don't want to use a drill press vise for fear of cracking the 40 yr. old phonolic plate. Here's the quick and easy rotor vise....

    IMG_20190311_155642.jpg

    IMG_20190311_155926.jpg
     
  11. MaxPete

    MaxPete New knee installed but still breakin’ her in.... Top Contributor XS650.com Supporter

    Ooohhhh....pretty!!
     
    Jim likes this.
  12. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    Jim
    Have you checked any of the rotors for balance before you rewound them?
    Reason I ask is a long time ago I used to rebuild alternators. I changed a few coils and never had a balance problem. I just made sure I indexed them the way they originally were. I'm just curios how well Mama Yama balanced them.
     
    Paul Sutton, MaxPete and Jim like this.
  13. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    Yeah... actually I have. Kinda surprising, but even some of the factory ones have a heavy spot on the knife edge. Not sure what to make of that.... either my knife edge works extremely well, or Yamaha didn't have very tight balance tolerances. I don't think age would have an affect so..... who knows.
    In the end, these motors shake so bad I don't think rotor balance has much of an affect.... mostly just OCD on my part. :rolleyes:
     
  14. Machine

    Machine Race the wind

    Better balancing than the original sure can't hurt tho :thumbsup:
     
  15. MaxPete

    MaxPete New knee installed but still breakin’ her in.... Top Contributor XS650.com Supporter

    ZACKLEY!!!
     
    Jim and Paul Sutton like this.
  16. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    Reason I asked is that if they were all out of balance the same they might have used the rotor to counterbalance the crank. Just food for thought.
     
    Jim likes this.
  17. MaxPete

    MaxPete New knee installed but still breakin’ her in.... Top Contributor XS650.com Supporter

    ....hmmmm...could be but I’d guess that the cranks are balanced well before the engine is assembled and waaaayyyy before the alternator rotor is installed.
     
    Jim likes this.
  18. Jim

    Jim "No...Try not. Do ... or do not. There is no try." Top Contributor XS650.com Supporter

    They're not. Some don't move at all on the knife edge.
     
    MaxPete likes this.
  19. GLJ

    GLJ Ran through life like my hair was on fire 650 time Top Contributor

    And they could have used the rotor to fine tune things.
    Ah maybe not these engines always had more than their share of vibrations. :D
    I think Jim's on the right track.
     
    MaxPete, Mailman and Jim like this.

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