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PMG manual page 33 June 2001 Rotor casting procedure Before starting, check that everything is ready: • the moulds are prepared with polish or release agent, • the magnets and the magnet disks are clean and bright (no grease), • 16 strips of CSM are ready to fit between the magnets • the stainless steel wire is cut to length and taped • the magnet positioning jig is ready The amounts of resin mentioned in this procedure are enough for two magnet rotors. 37. MAGNET ROTOR MOULD ASSEMBLY STAINLESS STEEL WIRE MAGNETS JIG MOULD STEEL DISK MOULD FOUR BOLTS • Place four bolts through the holes in the outer mould, from below (see diagram 37).
Steel wire is strong enough, but steel would take the magnetism from the magnet blocks. We use stainless steel because it is not magnetic and it does not spoil the effect of the magnets. Stainless steel wire cable is used on fishing boats. Before using any resin assemble the parts dry. Put the stainless steel rope around outside the magnets five times, and cut it off with a grinder or chisel. Tape it in several places so that it is in a coil, ready to drop into place later. PMG manual page 33 June 2001 Rotor casting procedure Before starting, check that everything is ready: • the moulds are prepared with polish or release agent, • the magnets and the magnet disks are clean and bright (no grease), • 16 strips of CSM are ready to fit between the magnets • the stainless steel wire is cut to length and taped • the magnet positioning jig is ready The amounts of resin mentioned in this procedure are enough for two magnet rotors.
Leave the rotor castings to set hard (several hours) before you remove them from the moulds. Be patient when removing the rotors from the moulds. Do not use violent hammer blows which may damage them. Hit the mould, and not the rotor. Four stages of the rotor casting procedure PMG manual page 35 June 2001 6. Assembly Rotor balancing Each rotor should be balanced, or the PMG will shake when it is turning. The whole PMG needs to be balanced again at the end, because the rotors may not be mounted exactly centrally.
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