Building the PMG
This manual describes how to build the PMG. Read right through it before starting.
Section 2. is a list of materials and tools for the job.
Section 3 explains how to build the special tools (called jigs) and the moulds which
are needed. You can build more than one PMG with them. There are many possible
ways to make these jigs and moulds, but there is only room in this manual to
describe one way to do it.
Section 4 is about the stator. It describes how to wind the coils of enamelled
copper wire, and cast them in resin, using the jigs and moulds.
Section 5 shows how to build the magnet rotors, using magnet blocks and steel
disks, set in another resin casting.
Section 6 shows how to assemble the parts into a whole PMG. It explains how to
build the mechanical parts, how to balance the rotors, and what is required to
connect the wiring from the stator.
Section 7 is about testing the PMG. It contains procedures for checking that it is
correctly balanced and ready to use. It describes the options for connecting up the
electrical output. It also explains how to connect the PMG to the battery.
Section 8 contains additional information about the use of polyester resins, and
about using the PMG for hydro power.
What this PMG can do
This PMG is made for small wind generators (see diagram 2). To build a complete
wind generator, you also need
• a tower : perhaps a steel pipe, supported with guy ropes,
• a 'yaw head' swivelling on the tower top,
• a tail, to keep it facing towards the wind,
• a set of blades, to turn it.
The spine of the PMG bolts on to the yaw head. The blade assembly fits on to the
front of the PMG. The yaw head and tail need to be so constructed that the wind
generator will turn from strong winds, to protect itself. (This manual does not
describe the blades, tower, or yaw head.)
PMG manual
page 5
June 2001