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The Hoon Generator For many people, FREE ENERGY is a “buzz word” that has no clear meaning. As such, it relates to a host of inventions that do something that is not understood, and is therefore a mystery. For others, it means “perpetual motion” and is therefore dismissed, without due consideration. What we present will show exactly what free energy is, how it works and how it can be applied in your everyday life….for light, heat and power. In the simplest sense, FREE ENERGY is any energy that is provided by the Natural World. This may include energy sources that you are familiar with, such as solar panels or wind generators, but also could include amazing technologies like a car powered by water-fuel, a battery charger powered by Magnets, or a home heating system powered by the Earth. The best FREE ENERGY systems deliver energy at no on-going cost to the user, without detrimental effects to the environment, and at extremely low costs for the maintenance and operation of the equipment. Yet, The Hoon Generator is that kind of generator that harvests a unique type of energy that few generators use and in a few moments you’ll find out why. It can offer you anything you need and more. Never stop fighting the bastards that can’t have enough of our hard earned money. The Hoon Generator is the first step toward a brighter future.
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INTRODUCTION The Sun & its Energy The sun's energy is the primary source of energy for all surface phenomena and life on Earth. Combined with the material of the Earth (including the molecules held close by the Earth's gravitational force called the atmosphere), this energy provides for the immense diversity of life forms that are found on the Earth. We will now look in detail at solar energy and its interplay with the constituents of the Earth's atmosphere.
Characteristics of the Sun
The sun is a medium, yellow star, consisting primarily of hydrogen at temperatures high enough to cause nuclear fusion. Nuclear fusion is a nuclear reaction in which hydrogen nuclei fuse together to form helium nuclei and release energy. In this state, some 120 million tons of matter--mostly hydrogen--are -3-
converted into helium on the sun every minute, with some of the mass being converted into energy. The size of the sun determines its temperature and the amount of energy radiated. Electromagnetic energy from the sun comes to Earth in the form of radiation. The term "radiation" simply denotes the fact that the energy travels as rays, that is, in straight lines. In general, the terms "solar energy" and "solar radiation" simply refer to energy from the sun. Electromagnetic energy is produced when electric charges change their potential energy. It is characterized by the property that it is pure energy, not requiring any matter (or medium) for its existence or movement. Electromagnetic energy can therefore travel through space (which is a vacuum), traveling at a speed that is the same for all forms of electromagnetic energy and is equal to the speed of light, 3 x 108 m/sec (or 186,000 miles per second). The sun radiates energy equally in all directions, and the Earth intercepts and receives part of this energy. The power flux reaching the top of the Earth's atmosphere is about 1400 Watts/m2. This measure simply means that on the average, one square meter on the side of the Earth facing the sun receives energy from the sun equal to that from fourteen 100 Watt light bulbs every second!
The sun is in a relatively stable state, and as far as we can tell, will continue to be so for about another three billion years. The sun and other stars do show periods of slightly higher than normal activity, detectable in our sun by an increase in sunspot activity. During sunspot activity, more energy reaches the Earth. The sun spends -4-
about a quarter of its time in a state with very few sunspots. It is suspected that the sun dimmed about ten times in the last 100,000 years causing "Little Ice Ages" (extended periods of unusually cold temperatures) of about a couple of centuries each. The last such quiescent state occurred in the late seventeenth century. The sun has also shone with considerable above-average brightness at least twice in our geological era: about 5,000 years ago, around the time of the beginning of the ancient civilizations of China, Minoa, Sumeria, and the Indus Valley; and about 1,000 years ago, when the temperatures of Northern England rose high enough to allow vineyards to flourish there.
Electromagnetic Spectrum - Basic Science
The entire region of electromagnetic energy distinguished by wavelength and frequency is called the electromagnetic spectrum. The propagation of the energy along the rays is in the form of a wave with the amount of energy alternating between high and low values, as in a water wave. Thus we say that light, heat, etc., travel in the form of waves. Wavelength can be defined as the distance between two successive peaks (or troughs) in waves of energy, while frequency is measured by counting the number of peaks that pass a given point every second.
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In the diagrams of the spectra in this section, we use two different scales in measuring wavelengths. The first is microns or micrometers (µm), which is equal to 10-6 meters. The other is nanometers (nm), equal to 10-9 meters. In discussing small ranges of the spectrum, we use units of nm, and in discussing the overall spectrum or larger regions, we revert to µm. Frequency is measured in units of cycles per second, or hertz (Hz). One cycle per second is equal to one hertz. In order of decreasing frequency (and increasing wavelength), the various regions of the electromagnetic spectrum are: gamma rays, x-rays, ultraviolet, visible light, infrared, microwaves, and radio waves. Electromagnetic energy from the sun consists mostly of a small amount of ultraviolet, all visible light, and some infrared. The full electromagnetic spectrum is depicted in Figure 2. Table 1 gives the same information, as well as some technological applications.
Figure 1: The electromagnetic spectrum. (from Lawrence Berkeley National Laboratory)
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Name of Region
Wavelength Range (in m, µm, and nm)
Frequency Range
Technological Applications / Role in Nature
Gamma Rays
10-14 to 10-10 m 10-8 to 10-4 µm 10-5 to 10-1 nm
3x1022 to 3x1018 Hz
Radiation therapy
X - Rays
10-14 to 10-8 m 10-8 to 10-2 µm 10-5 to 10 nm
3x1022 to 3x1016 Hz
Radiation therapy; diagnosis (lower frequencies)
Ultraviolet Rays
10-8 to 4x10-7 m 10-2 to 0.4 µm 10-5 to 400 nm
3x10 to 0.75x10 Hz
Tanning; Promotes production of Vitamin D in human skin; photosynthesis in plants
Visible Light
4x10-7 to 8x10-7 m 0.4 to 0.8 µm 400 to 800 nm
0.75x1016 to 0.375x1016 Hz
Lamps for seeing (Eyes respond to this range)
Infrared
8x10-7 to 10-3 m 0.8 to 103µm 800 to 106 nm
0.375x1016 to 3x1011 Hz
Infrared photography
Radio Waves
10-4 to 106 m
3x1012 to 300 Hz
Communication devices
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Table 1: Regions of the entire electromagnetic spectrum and general applications. Note that the regions are not strictly delineated. We have specialized sensory organs that only detect some parts of the spectrum. For example, the eye detects visible light, and even distinguishes different wavelengths within the spectrum of visible light as color! The skin perceives radiation from the infrared region of the spectrum as heat. Note that sound is not a form of electromagnetic energy. Because sound is really the energy of the motion of molecules through a medium (mechanical energy), it cannot travel through a vacuum. As we already noted, electromagnetic energy has no need for a medium through which to travel, and can therefore travel through space from the sun to reach the Earth. Different molecules absorb different regions of electromagnetic energy preferentially. For example, the water molecule preferentially absorbs certain wavelengths in the microwave region of the electromagnetic spectrum. This preference is the basis of the efficient cooking of food by microwave ovens. Calcium, -7-
a primary constituent of bones, absorbs energy in the x-ray region more strongly than do the water or carbon in the cells of ordinary tissue, allowing for the use of x-rays to generate images that show unevenness such as broken bones or tumors. The chlorophyll molecule in green plants absorbs mostly ultraviolet (and also some blue violet, and red light) and uses this energy for photosynthesis. Most of the green light in sunlight is reflected by leaves, making them appear green to our eyes.
Solar Spectrum
The range of electromagnetic energy emitted by the sun is known as the solar spectrum, and lies mainly in three regions: ultraviolet, visible, and infrared. The solar spectrum extends from about 0.29 µm (or 290 nm) in the longer wavelengths of the ultraviolet region, to over 3.2 µm (3,200 nm) in the far infrared. Small amounts of radio waves are also given off by the sun and other stars. In fact, if the sun's image is made from its radio waves, it appears 10% larger than if its image is made from visible light. There are some "cooler" stars that give off mostly radio waves and no visible radiation.
The range of energy given off by a star depends upon the temperature and size of the star. Smaller, hotter stars (called "white dwarfs") give off more energy in the blue region and appear "whiter" than our yellow sun. Rigel, a star in the constellation Sirius, is a white dwarf. Larger, cooler stars, called "red giants," emit more light in the red region, and are exemplified by Antares and Betelgeuse. Note that even a "cool" star still has a temperature of a million degrees or so. -8-
While the sun does emit ultraviolet radiation, the majority of solar energy comes in the form of "light" and "heat," in the visible and infrared regions of the electromagnetic spectrum. As shown in Table 1, visible light spans the relatively narrow range of 0.4 to 0.9 µm (or 400 to 700 nm). Light is special to humans and many other animals due to the evolution of the eye, a sensory organ that detects this part of the solar spectrum. As noted earlier, our eyes even recognize parts of the visible light spectrum as the sensations of color. Thus 400 nm radiation is perceived by the eye as violet, and 600 nm radiation is perceived as red. However, The Hoon Generator’s power comes from other sources.
Electromagnetic Radiation
Electromagnetic radiation is a wonderful thing. It brings us heat and lights up our day, it brings us radio and television and carries our telephone conversations. It brings us the Sun's energy which is needed by all plants for photosynthesis and growth. It brings warmth to the inhabitants of the Earth's animal kingdom and to some of them to tan their bodies. We also use it to see through solid bodies, to find our way around the planet and to cook our food. Yet it has one more use. In a tremendous intellectual leap, in 1873 James Clerk Maxwell suggested the existence of electromagnetic waves and worked out mathematically what their properties might be before anybody had ever observed, or even thought of, such a phenomenon. Since then, communications engineers have performed miracles harnessing this radiation for a myriad of uses.
Electromagnetic radiation has the following interesting properties
It can be found in nature.
It does not require a medium for propagation.
It travels with the speed of light.
It carries energy as it propagates. The higher the frequency, the higher the energy associated with the wave.
It can transfer its energy to the matter on which it impinges.
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Its transferred energy may be sufficient to break chemical bonds, ionising the matter on which it impinges.
Its propagation obeys the inverse square law.
It can be used to carry information.
It can be broadcast outwards to reach many locations or it can be formed into beams to reach a particular spot.
It can be reflected or refracted.
It can be split and recombined to form diffraction patterns.
It can travel great distances. The radiation resulting from a simple100 volt, 1 MHz sine wave fed into a suitable antenna can be detected as far away as the next planet.
It travels in straight lines.
It can be bent around the Earth's circumference by reflection from the ionosphere.
It can pass through walls.
It can be captured by placing a metal rod, a loop, parabolic metal dish or horn in its path and it can be launched into the atmosphere with the same tools. And these are the reasons The Hoon Generator is so efficient. It harvests the energy regardless of its location, weather conditions and other such interferences.
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Part List Part
Type, Model # or MFG P/N Generator Core
Quantity
Stator
140 Laminations 24 gauge (.025”) [0.64mm] type M19 Steel w/C5 coating, 3-1/2” stack, Welded, Bolted, or Bonded (Cut at same time, from same lamination sheets as stator)
(1) (See Drawing)
Rotor
Spacer Blocks 1-1/2” Aluminum 6061-T6, G10[38.1mm] x 1-1/2” [38.1mm] FR4, Clear Polycarbonate, x 4-3/8” [111.125mm] Accoya® Acetylated Wood
(1) (See Drawing)
(8) (See Drawing)
8” [203.2mm] Bolts, ¼” [M6] Ø, ¼ -28 [M6x0.75] Thread, Grade 8 [Class 10.9]
Instock Fasteners P/N 1050095555
(8)
Nuts/Washers/Lockwashers
¼ -28 [M6x0.75] Grade 8 [Class 10.9] Hex Nuts/Flat Washers/Split Lockwashers
8 pcs. each
Shafting 7/8” [22.225mm] dia. x 11.0” [279.4mm] Long w/Standard 3/16” [4.7625mm] x 3/32” [2.38125mm] Keyway
Trukey P/N C1045 TGP (turned/ground/polished)
7/8” [22.225mm] dia. x 11” [279.4mm] or 12” [304.8mm] length
Bonding Compound for Shaft to Rotor
LOCTITE 648 Retaining Compound (Cat. No. 64836)
(1) (50ml Bottle)
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Primer/Activator (use with bonding compound)
Loctite 7471 (Cat. No.142474)
(1) (150ml Aerosol)
Bearings
4-Bolt Flange Mount, 7/8” Bore, P/N FC-7/8-RHP (preferred), or 3-Bolt Flange Mount, 7/8” Bore, P/N SBTRD205-14G
(2)
Bearing
Bolts 5/16” [M8] x 1-3/4” [44.45mm] Carriage Bolts
(6)
Nuts/Washers/Lockwashers 5/16” [M8] Hex Nuts/Flat Washers/Split Lockwashers
(6 pcs. each)
Mica Tape
1.00” [25.4mm] x 50YD [45.72M] MICA77956X1X50
(2) Rolls
Magnet Wire #12 gauge
Round Wire, Type HTAIHSD REA Pulse Shield® Inverter Duty (critical part!) ~620’ [188.976M]
(19.8 lbs./1000’)
Magnet Wire #20 gauge
Round Wire, Type HTAIHSD, REA Pulse Shield® Inverter Duty (critical part!)
~5200’ [1584.96M] (3.1 lbs. [1.406kg] /1000’ [304.8M] )
Mica Plate
NEMA 6 (36” [.9144M] x 36” [.9144M] x .030” [0.762mm] )
(16) (See Drawing)
PTFE (Teflon) Sleeving (tubing) for #20 HTAIHSD Wire each) PTFE (Teflon) Sleeving
Alpha Wire P/N TFT20011 (natural)
(4) pieces (18” [457.2mm]
(tubing) for #12 HTAIHSD Wire Alpha Wire P/N TFT20019 (black)
(4) pieces (18” [457.2mm] each)
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Tape, White, 1” [25.4mm] Fiberglass, Hi-Temp (outer wrap)
Intertape P/N RG48
(2) Rolls
Tape, 1” [25.4mm] High Cut-Through Strength Mylar (Polyester), or Kapton
3M P/N 850 (Mylar, 1.9 mil), or Caplinq P/N PIT2A/25.4 (Kapton, 2 mil, tan color)
(2) Rolls
Nomex Corner Insulation
Torelco (custom made)
(16) pcs., (DuPont Type 418)
End Plates and Shrouds Reinforced Resin Laminated or Cast Sheet Material (for 2 end plates)
G10/FR4 (preferred), Phenolic3 types CE or LE, or transparent (clear) Polycarbonate
Reinforced Resin Laminated or Cast Sheet Material (shrouds)
G10/FR4 (preferred), Phenolic types CE or LE, or transparent33 (clear) Polycarbonate
(1) sheet ½” [12.7mm] thick x 3’ [.9144M] x 4’ [1.292M] (makes 2 plates). (See Drawing) (2) 1/8” [3.175mm] thick x 5.875” [149.225mm] Ø, with 7/8” [22.225mm] Ø hole dead center (See Drawing)
Mounting Rail Angle aluminum
1 ½” [38.1mm] x 1 ½” [38.1mm] x 4’ [1.2192M] Long. 1/8” [3.175mm] Thick
(1)
Wood or Laminate Parts for Platform (Base) Generator Baseplate
18” [457.2mm] (W) x 36” [.9144M] (L) x 1.5” [38.1mm] (Thick)
Core Mounting Shoe
6.5” [165.1mm] (W) x 15” [381mm] (L) x 1.50” [38.1mm] (Thick)
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(1) If using wood, make from 2 pcs. of ¾” [19.05mm] thick quality plywood. Bond (screw and glue) together with opposing grain direction (1)
Lag Bolts (Generator Core to mounting shoe)
(¼” [M6] x 2.5” [65mm]
(10)
Washers/Lockwashers
¼” [M6] Flat Washers/Split Lockwashers
(10 pcs each)
Drive System V-Belts and Pulleys V-Belt, Goodyear 4L430 Pulley, 1 Groove, 3” [76.2mm] x 7/8” (or 5/8”) Bore, Type A (Motor) Pulley, 1 Groove 2.50” [63.5mm] x 7/8” Bore, Type A (Generator)
GDYR_4L430 (cogged belt) AK30 x 7/8” Bore (bore size could also be 5/8” to match motor shaft)
(1)
AK25 x 7/8”
(1)
(1)
Drive Motor DC PM Variable Speed, 1.0 /8” or 7/8” shaft, with HP, 2500 RPM, 90V or sliding or slotted base. 180V armature (depending Leeson Model # 4D28FK5 on selected system voltage) (90V armature), 5 #4D28FK6 (180V armature)
(1)
Bolts 5/16” [M8] x 2-1/4” [60mm] Carriage Bolts
(4)
Motor Mounting
Nuts/Washers/Lockwashers 5/16” [M8] Hex Nuts/Flat Washers/Split Lockwashers
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(4 pcs. each)
Variac,
120/240V Input, 0-280V Output, 9.5 Amps STACO Type 1520
(1)
Switch, Start/Run
Carling #TIGM51-6SBLNBL (DPDT Center Off, 15 amp, 240V)
(1)
Capacitors Capacitor, Filter - optional anti-hum for drive motor (if needed)
W.W. Grainger #2MDZ6 (40uF, 440 VAC, quickconnect terminals
(1)
Capacitors, Resonant Tank 0.15uF [150nF], 3000 Volt, Tubular Axial Polypropylene
Cornell Dubilier #940C (preferred) High dV/dt for pulse applications
(72) 8 capacitors x 9 rows for initial value of 0.169uF [169nF] (see class 3 & class 5)
Protection Gap Terminal Lug, 1-Hole mount Drill Rod, ¼” [6.35mm]Ø Type A2
T&B Blackburn #L70
(2)
Metals Depot #05827
(2) Cut-to-Length (1”) [6.35mm]
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The stator It represents the generator’s core. The stator is built using 140 laminators of 24 gauge electrical steel. They form a 3-1/2 inches stack, with a 4 pole configuration. Inside the stator you must position the rotor (which has 2 poles). Both sator and rotor are tig welded in 4 places, as show in Figure 1. It is not necessary to weld the lamination stack. This is done only to maintain alignment of the laminations during shipping and handling. The lamination stack can be welded, bonded, or simply bolted together.
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End plates The end plates need to be manufactured out of fiberglass reinforced epoxy laminate [other types of laminate material can be used, such as Grade CE (cotton/epoxy), or Grade LE (Linen/epoxy)]. Clear polycarbonate (not acrylic) can also be used if you would like your end plates to be transparent. They must be constructed of insulated material, but need to have a strong structure because it will support all the generator’s components (bearings, shaft, rotor, and stator). You can use the same material used to make circuit boards, or any other material that will support the resulting weight. The dimensions of the end plates are: 17
Thickness – 0.5” Surface – 4.15” x 16.5” One end needs to have a 15” radius The central hole – 2.450
Please note: If using the preferred 4-bolt bearing housings, start with center hole diameter of 2-7/8” (2.875”). Center hole (and bearing mounting holes) may require further enlargement or slotting to provide sufficient bearing adjustability when centering rotor in stator bore.
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Bearings An inner ring with set screws should be placed on the bearings. This will help the bearings to be attached to the shaft. Housing is cast iron with a grease zerk for relubing the bearing. We used a particular 4-bolt flange type bearing/housing (see parts list) because it is very flat, and worked better for mounting bearings on the inside of the end plates (toward the rotor), but 2-bolt or 3-bolt bearings/housings can also be used. Bearings can also be mounted on the outside of the end plates, which may require the shaft to be slightly longer (12” length should be sufficient in any case).
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Resonant (Tank) Capacitors The primary tank circuit capacitors are a critical part of the system. The initial capacitor bank configuration on our prototype uses 72 tubular film type caps, 0.15uF [150nF] each (see parts list). Each cap is rated for 3000V. The bank is configured with 9 parallel rows of 8 series wired capacitors. Each series string can withstand up to 24,000 Volts, and total capacitance value is adjusted by making and breaking the connections that parallel the rows (see included schematic “initial resonance cap value.pdf”, and cross-reference table “tank capacitor values.pdf”). The value of these 20
capacitors will be adjusted to tune the frequency/RPM of the generator. Fine tuning (of small increments of capacitance value) can be accomplished by jumpering (or switching) single capacitors in or out in series with any of the 9 series strings of capacitors. This bank can be adjusted for values between about 0.019 and 0.169uF [19 and 169nF]. A value of about 0.169uF [169nF] will establish resonance near 2,400 RPM on the rotor shaft, which is in the ideal speed range for the machine’s mechanical setup. The machine in the Witts 40kW demo video is running at about 2450 RPM. Ours is only a suggested capacitor bank configuration. Other setups may be designed and used according to your preference and budget. The best information we have at this point in development indicates experimental values will be between about 0.03 and 0.3uF [30 and 300nF], and the final capacitor value may be just around 0.1uF [100nF].
Capacitors Capacitors are one of the most important parts of the generator. Our initial configuration uses 12 capacitors, 2,5 uf (microFarads) each. Each capacitor is rated for 2000 V. You need to wire the capacitors in series for them to be able to withstand up to 25,000 V in the primary circuit. The frequency of the generator will be tuned and adjusted by the value and quantity of the capacitors.
Variac The variac will allow you to control the drive motor speed which will consequently lead to controlling the power of the system. The variac will be used during the construction of the generator and while tuning the parameters of the generator. It can also be used prior to self-running set-up when it can be replaced with the smaller, lighter electronic motor drive circuit board. Use of a variac is important when attempting to self-loop because the variac output is available instantly when the input is energized, and switching the motor (and variac) from mains supply to generator output must be done quickly to prevent the machine slowing down and dropping out of resonance before the switchover is complete. Electronic motor drives have a certain amount of delay before output is available after energizing the input. However, once self-looping is established, we’ll know how much delay can be tolerated, so an electronic drive may be an option at that point, which would reduce the weight, bulk, and cost of the machine.
21
The control circuit board for the drive motor The drive motor control circuit board is a standard motor drive manufactured my KB Electronics – it is industry standard SCR type DC. You can mount the control board in the console box. It will help you adjust the motor speed, as it is provided with a speed control potentiometer.
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The layout of the end plate You can use the bare core to fix the proper location to drill the core mounting holes on the end plates. After finishing the end plates, place one of them onto a flat surface that can support at least 100 lbs. Place the bare core over the end plate and align the center bore of the core with the center hole in the end plate. When mounting the core on the endplates, it should be oriented with the pole pieces at 45° to the generator base for the lowest profile. Make sure the pole pieces are right to the edge of the radius at the top of the end plate. You can use an extra long drill bit to drill the 8 mounting holes. The same process must be applied to the other end plate. You can use an extra long drill bit to make the 8 mounting holes. Apply the same process to the other end plate. Make sure the final assembly has the parts in the same orientation and all mounting bolts align properly. Do not forget to mark the in-facing and out-facing sides of the panels.
Core assembly After the stator and rotor is welded and the holes are in place, you can start bolting the 8 spacers and wrap the core with 2 types of tape. You need to wrap 2 layers of mica tape around the steel core (the round part). Over it, wrap 1 layer of 1” reinforced, high-strength black tape. These 3 layers will bring the thickness needed to 17 mil. Mind that the corners of the pole pieces have no openings in the insulation for the wire to fall down into contact with the steel. If this happens, the coil will be shortcircuited.
23
Mica Plate Cuts (16 pieces)
Installing Mica Plates After you’ve cut 16 C-shaped mica plates, install them on the top and bottom of each pole piece (front and back). We used a small amount of contact cement to hold them in place for the rest of the processing (see photos), but they can also be taped in place with the reinforced Mylar tape. Mica plates (and corner insulation pieces) are installed after core taping and before winding. Make 16 pcs. of corner insulation from high voltage insulating paper (such as DuPont Nomex type 418 or equivalent) at 0.015 to 0.025” thickness. Install these in the corner between mica insulating plates and mica tape wrap (see drawing). This is provided by Torelco when ordering a fully-processed core. Be very mindful at the corners of the pole pieces making certain there is no opening in the insulation for the wire to fall down into contact with the bare steel. If this happens, the coil will be short-circuited.
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Wiring You have 2 options: 1. You can wind the core yourself, 2. You can commission a toroidal winding service. To make thing easier, you can request them to process the entire core if you supply the materials (mica tapes and plates, corner insulation, aluminum spacers, bolts, outer taping, etc.). Proper winding is critical in either choice.
25
26
You need to install Teflon sleeving on the first complete turn of each winding of the #20 wire and fiberglass/PVC sleeving on the #10 wire Two coils of 3100 turns each of #20 wire are wound on opposing sides (left and right), and 2 coils of 350 turns each of #10 wire on the other sides (top and bottom). Leave about 3 feet of wire at the start of each winding and also at the finish for lead wires. Enough sleeving must be used to make sure the lead wires are fully insulated where they exit through the back end panel. Make sure the end leads of each coil to prevent them from unraveling while handling. 27
Outer Wrap Taping Each coil must be tightly and securely wrapped with a 1” layer white fiberglass. Make sure all wire is covered and all tape is perfectly butted up against the 4 pole piece.
28
29
Other electrical components:
30
31
32
33
34
35
Generator Assembly Steps
Rotor/Shaft/Shroud Assembly Drawings are provided for the shaft showing an optional spline operation that can be used to mount the rotor to the shaft, if desired. We used Loctite 648 industrial adhesive (with activator), which is effective with close fitting parts.
Drill a 7/8” center hole, and two ¼” mounting holes into the shroud disks (mounting holes are lined up with the holes in the rotor). Slide one disk onto the shaft on each side of the rotor. Use 2 4” or 4-1/4” long ¼ - 28 through-bolts and nuts to bolt both shrouds to the rotor. The size of the bolts must be exact because longer bolts can imbalance the generator. The shrouds’ purpose is to quiet close to zero the windage noise generated by the spinning rotor.
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Bearings Bearing must be mounted to the inside of the front and rear end plates. Each bearing must be centered on the 2.450” hole in the center of the plate. Drill the holes oversize for the mounting bolts. This ensures adjustability of the position of the shaft at final assembly. You may need to slightly move the bearings in order to center the rotor in the bore of the generator. As the distance between the rotor and the stator is very small – 0.10” – the rotor will need to be placed so it will not rub on the stator bore. Do not complete the rotation at this time – finger tighten it. One option is to bring the leads from the coils out directly through holes drilled in the rear end plate. Any other way is acceptable. Next, we will present this technique:
Core Assembly We opted to bring the leads from the coils out directly through holes drilled in the rear end plate. You may decide to bring the leads out a different way. Here are the steps for our method: 1) Place the pre-drilled front end plate (the one without the holes for the coil wire leads) on top of 4 wood blocks, 1-1/2” thick x 3-1/2” wide x 6” long arranged in a cross, and placed on a work surface (it needs to be flat and it needs to support up to 130 lbs/60 kg). Position the wood blocks under the end plate evenly without covering any of the pre-drilled holes. 2) If needed, ask another person to help you place the fully processed core (about 90 lbs.) down onto the pre-drilled end plate. The wire leads need to be facing up. The center bore of the core must be lined up with the center hole in the end plate. Next line up the mounting holes. Make sure the wire leads are oriented accordingly. 37
Use a couple of long ¼” rods or 2 of the long mounting bolts and push them through the stator, into 2 mounting holes on opposite sides of the end plate. In this way, line up all 8 mounting holes in the stator with all 8 mounting holes in the end plate, using the long rods or bolts. 3) Leaving the 2 rods (or bolts) in place momentarily to maintain alignment, insert the longer end of the rotor/shaft/shroud assembly through the stator bore and into the front pre-mounted bearing. Let the rotor assembly drop through the bearing gently to the bottom, then rotate it to align with 2 of the stator poles. Without moving the core, front end plate, or rotor, gently remove the 2 long alignment rods (or mounting bolts). Now take the rear end plate (with pre-mounted bearing) and fish the 8 lead wires through the pre-drilled holes, as you lower it over the end of the rotor shaft. Take care not to pinch, bunch up, or crush any of the wire leads as you lower it into place. Once the rear end plate is down in contact with the stator assembly, install the 4 outer mounting bolts, washers, and nuts, and tighten securely. The core assembly must now be placed upright to reach the 4 inner mounting bolts. With assistance, place the assembly upright onto the raised portion of the base (mounting shoe), and install the 4 inner mounting bolts.
Set-up and testing Wiring Notes: The generator output (secondary) can be wired in series (220, 230-240V), or parallel (110, 115, 120V). For the series connection shown on the schematic, the start leads from each coil are connected together. This connection provides the highest voltage output from the windings. If using a parallel connection for lower voltage/higher current, be careful to connect the four leads with polarity opposed (start lead of one coil connected to finish lead of other coil). The variac we used can be wired for 120 or 240 volt input, and provides 0-280 volts output, at up to 9.5 amps. This is a versatile variac and can be used with either a 120 or 240 volt system. The output of the variac is connected to a 1000 volt, 25 Amp full-wave bridge rectifier to power the variable speed DC drive motor. Optionally, a 30-50uF, 400-450 Volt filter capacitor can be added across the bridge rectifier to filter out any AC hum in the motor. Starting with the wiring setup as shown in the schematic, prepare the series/parallel capacitor bank, but do not connect to primaries at this time. This will prevent resonance momentarily. Connect input power to the variac. We started with a full 240 volt series wired system, but parallel 120 volt wiring can also be used. Test mechanical the assembly by spinning up the motor/rotor/belt and observing the operation. Adjust variac voltage from zero to about ¾ through its range. The active rpm range is under 3000 rpm, so we don’t need to spin very fast. Assure there is no stack rub (rotor scrubbing on stator), or other mechanical issues that need to be corrected for smooth operation. 38
When proper mechanical operation is assured, connect the series/parallel capacitor bank. The recommended initial configuration of 72 (seventy-two) 0.15 uF (150nF), 3000 volt capacitors gives us .16875uF (168.75nF), that will withstand up to 24,000 volts. This initial value should be in the range to produce resonance at approx. 2400 RPM (about 160Hz). Be sure to apply a load on the output of the generator at all times. We recommend starting with the generator output wired in series, and four (4) 100 Watt/240 Volt incandescent lamps wired in parallel for initial load. As the machine spins up to resonance, the sound will change, and the rotor speed will lock into the resonant frequency. At this point any further increase of the motor speed control will change the speed only slightly, but the additional mechanical power input will drive the core deeper into resonance, thereby increasing the power output. With a single control, the voltage and current (power) can be increased or decreased. In the generator, the exciter coil is precisely tuned to 1.3 MHz resonant frequency. The exciter coil is a form of antenna, which effectively provides a conduction path from the quantum field (zero point) into the generator core. This has the effect of polarizing and electrifying the core, which increases power output. After the Hoon Generator is first built, the spark gap on the exciter coil should be adjusted (with power off) to between .005” and .010”. Start the generator and let it spark for 2-3 seconds, and repeat this 4 or 5 times. Do this whenever starting the generator for the first few weeks of operation.
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The wiring of the generator:
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The electrical schematic:
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Schematics 1. Main Part
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2. End Plate
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3. Second End Plate
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4. Fixture of the Device
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5. Rotor Assy
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6. Stator Assy
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7. The Generator’s Schematics
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8. End Plate
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9. The Shaft
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10. The Rotor
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11. The Shroud
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12. The stator
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