<snip
  I also did away with one tooth to better simulate
  what will happen in the final flyaway configuration.
  There will be only one trigger tooth and four mag pickups.
  Two for ignition (about 22 degrees BTDC) and two for fuel
  injection (about 90 degrees BTDC). The angular position of
  the pickup relative to top dead center will adjust the
  timing of both 555 fuel injection and ignition.

  Paul Lamar

Paul -

You crack me up.  Just months ago when I brought up this scenario for
triggering injectors and ignition, you complained that it had too many
sensors, and that sensors weren't cheap.  :)  At the time I brought it up
more as an illustration of the rotary's simple timing arrangement than as a
design proposal.

But hey, I'm glad its value as a simple, no-moving-parts system has become
apparent.

I guess I ultimately agree that it DOES have too many sensors, too much
shielded wiring, and too many critical clearances to set.  A timing wheel
with a simple counter & multi-trigger circuit would be more pragmatic, I
think.

Just my thoughts.

-Vince Orton

Some times it takes a long time for a good idea to sink into my brain :)
There is some redundancy here. If one sensor fails it will only affect one
rotor.

These sensors are expensive. Klaus tells me he took one apart and it had a
zillion turns of very fine wire. He uses tiny rotating magnets and hall
effect sensors instead because they are cheaper. Trouble with that is Hall
effect sensors need voltage to work.

I am looking for a cheap source for these magnetic sensors and I may attempt
building my own. They appear easy to make. Materials are cheap.
You need some magnet wire:

http://webtronics.stores.yahoo.net/32mawi1lbspm.html

A round cylindrical bar magnet:

http://www.kjmagnetics.com/categories.asp?gclid=CJXmz-DonZgCFRwDagoddmh2Aw


And a housing made from steel threaded pipe used in lamps:

http://www.nationalartcraft.com/subcategory.asp?gid=1&cid=24&scid=437

Here are the dwgs and some files.

Paul Lamar


Paul, you might search Ebay for "coil winding machine" there are some
fairly inexpensive machines out there.
Or If you think this will be an ongoing need for our rotary projects, and
you haven't the time, I'll take on the coil project invest in a winder and
some raw materials and start production.
What do you think?
C. Smith


That is a good idea. The need for these things is not going away.
It will take some experiment to come up with a 300 volt coil.
Revmaster did it so it must be possible.

BTW one or more of these things looking at the ring gear would make
a good low cost back up alternator. The magnets do not have to rotate.
They can be built into the coil. All you need are changes in the
magnetic field and the ring gear starter teeth will provide that.

Paul Lamar

I'm on it, should be in production in a week or 2.
C. Smith

BTW Craig I measured the resistance of the stock pick up.
It appears to be 1.2K  Knowing the resistance of 32 ga
magnet wire per foot one should be able to calculated the number
of feet of wire required. I think it is .16 ohm per foot.
If so you will need 7000 feet.
http://www.bcae1.com/wire.htm
http://amasci.com/tesla/wire1.html

ALSO SEE: WIRE SUPPLIERS, HV CABLE & DIODES

AWG       Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps

0000       459.99    2.1740    11.684    211592    0.0490     20402    1.5613    0.0001    640.48    282.12    423.18
000        409.63    2.4412    10.405    167800    0.0618     16180    1.9688    0.0001    507.93    223.73    335.60
00         364.79    2.7413    9.2657    133072    0.0779     12831    2.4826    0.0002    402.80    177.43    266.14

AWG       Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps

0         324.85    3.0783    8.2513    105531    0.0983     10175    3.1305    0.0003    319.44    140.71    211.06
1         289.29    3.4567    7.3480     83690    0.1239    8069.5    3.9475    0.0005    253.33    111.59    167.38
2         257.62    3.8817    6.5436     66369    0.1563    6399.4    4.9777    0.0008    200.90    88.492    132.74
3         229.42    4.3588    5.8272     52633    0.1970    5075.0    6.2767    0.0012    159.32    70.177    105.27
4         204.30    4.8947    5.1893     41740    0.2485    4024.7    7.9148    0.0020    126.35    55.653    83.480
5         181.94    5.4964    4.6212     33101    0.3133    3191.7    9.9804    0.0031    100.20    44.135    66.203
6         162.02    6.1721    4.1153     26251    0.3951    2531.1    12.585    0.0050    79.460    35.001    52.501
7         144.28    6.9308    3.6648     20818    0.4982    2007.3    15.869    0.0079    63.014    27.757    41.635
8         128.49    7.7828    3.2636     16509    0.6282    1591.8    20.011    0.0126    49.973    22.012    33.018
9         114.42    8.7396    2.9063     13092    0.7921    1262.4    25.233    0.0200    39.630    17.456    26.185

AWG       Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps

10         101.90    9.8140    2.5881     10383    0.9989    1001.1    31.819    0.0318    31.428    13.844    20.765
11         90.741    11.020    2.3048    8233.9    1.2596    793.93    40.122    0.0505    24.924    10.978    16.468
12         80.807    12.375    2.0525    6529.8    1.5883    629.61    50.593    0.0804    19.765    8.7064    13.060
13         71.961    13.896    1.8278    5178.3    2.0028    499.31    63.797    0.1278    15.675    6.9045    10.357
14         64.083    15.605    1.6277    4106.6    2.5255    395.97    80.447    0.2031    12.431    5.4755    8.2132
15         57.067    17.523    1.4495    3256.7    3.1845    314.02    101.44    0.3230    9.8579    4.3423    6.5134
16         50.820    19.677    1.2908    2582.7    4.0156    249.03    127.91    0.5136    7.8177    3.4436    5.1654
17         45.257    22.096    1.1495    2048.2    5.0636    197.49    161.30    0.8167    6.1997    2.7309    4.0963
18         40.302    24.813    1.0237    1624.3    6.3851    156.62    203.39    1.2986    4.9166    2.1657    3.2485
19         35.890    27.863    0.9116    1288.1    8.0514    124.20    256.47    2.0648    3.8991    1.7175    2.5762

AWG       Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps

20         31.961    31.288    0.8118    1021.5    10.153    98.496    323.41    3.2832    3.0921    1.3620    2.0430
21         28.462    35.134    0.7229    810.10    12.802    78.111    407.81    5.2205    2.4521    1.0801    1.6202
22         25.346    39.453    0.6438    642.44    16.143    61.945    514.23    8.3009    1.9446    0.8566    1.2849
23         22.572    44.304    0.5733    509.48    20.356    49.125    648.44    13.199    1.5422    0.6793    1.0190
24         20.101    49.750    0.5106    404.03    25.669    38.958    817.66    20.987    1.2230    0.5387    0.8081
25         17.900    55.866    0.4547    320.41    32.368    30.895    1031.1    33.371    0.9699    0.4272    0.6408
26         15.940    62.733    0.4049    254.10    40.815    24.501    1300.1    53.061    0.7692    0.3388    0.5082
27         14.195    70.445    0.3606    201.51    51.467    19.430    1639.4    84.371    0.6100    0.2687    0.4030
28         12.641    79.105    0.3211    159.80    64.898    15.409    2067.3    134.15    0.4837    0.2131    0.3196
29         11.257    88.830    0.2859    126.73    81.835    12.220    2606.8    213.31    0.3836    0.1690    0.2535

AWG       Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps

30         10.025    99.750    0.2546    100.50    103.19    9.6906    3287.1    339.18    0.3042    0.1340    0.2010
31         8.9276    112.01    0.2268    79.702    130.12    7.6850    4145.0    539.32    0.2413    0.1063    0.1594
32         7.9503    125.78    0.2019    63.207    164.08    6.0945    5226.7    857.55    0.1913    0.0843    0.1264
33         7.0799    141.24    0.1798    50.125    206.90    4.8332    6590.8    1363.6    0.1517    0.0668    0.1003
34         6.3048    158.61    0.1601    39.751    260.90    3.8329    8310.8    2168.1    0.1203    0.0530    0.0795
35         5.6146    178.11    0.1426    31.524    328.99    3.0396     10480    3447.5    0.0954    0.0420    0.0630
36         5.0000    200.00    0.1270    25.000    414.85    2.4105     13215    5481.7    0.0757    0.0333    0.0500
37         4.4526    224.59    0.1131    19.826    523.11    1.9116     16663    8716.2    0.0600    0.0264    0.0397
38         3.9652    252.20    0.1007    15.723    659.63    1.5160     21012     13859    0.0476    0.0210    0.0314
39         3.5311    283.20    0.0897    12.469    831.78    1.2022     26496     22037    0.0377    0.0166    0.0249

AWG       Dia-mils  TPI       Dia-mm    Circ-mils Ohms/Kft  Ft/Ohm    Ft/Lb     Ohms/Lb   Lb/Kft    *Amps     MaxAmps

40         3.1445    318.01    0.0799    9.8880    1048.9    0.9534     33410     35040    0.0299    0.0132    0.0198




------------------------

From richard.quick at slug orgSat Sep  2 13:01:29 1995
Date: Mon, 28 Aug 1995 22:24:22 -0600
From: Richard Quick
Reply to: usa-tesla@usa.net

Subject: AWG Wire Chart

AWG       D.C. OHMS     WIRE DIAM   APPROX. TURNS PER      FEET PER
SIZE     PER 1000 FT     INCHES     INCH, SOLID ENAMEL      POUND
                                   COVERED
1        .1264          .2893         X                    3.947
2        .1593          .2576         X                    4.977
3        .2009          .2294         X                    6.276
4        .2533          .2043         X                    7.914
5        .3195          .1819         X                    9.980
6        .4028          .1620         X                   12.58
7        .5080          .1443         X                   15.87
8        .6405          .1286         7.6                 20.01
9        .8077          .1144         8.6                 25.23
10      1.018           .1019         9.6                 31.82
11      1.284           .0907         10.7                40.12
12      1.619           .0808         12.0                50.59
13      2.042           .0720         13.5                63.80
14      2.524           .0641         15                  80.44
15      3.181           .0571         16.8                101.40
16      4.018           .0508         18.9                127.90
17      5.054           .0453         21.2                161.3
18      6.386           .0403         23.6                203.4
19      8.046           .0359         26.4                256.5
20     10.13            .0320         29.4                323.4
21     12.77            .0285         33.1                407.8
22     16.20            .0253         37.0                514.2
23     20.30            .0226         41.3                648.4
24     25.67            .0201         46.3                817.7
25     32.37            .0179         51.7               1031
26     41.02            .0159         58.0               1300
27     51.44            .0142         64.9               1639
28     65.31            .0126         72.7               2067
29     81.21            .0113         81.6               2607
30    103.7             .0100         90.5               3287
31    130.9             .0089         101                4145
32    162.0             .0080         113                5227
33    205.7             .0071         127                6591
34    261.3             .0063         143                8310
35    330.7             .0056         158               10480
36    414.8             .0050         175               13210
37    512.1             .0045         198               16660
38    648.2             .0040         224               21010
39    846.6             .0036         248               26500
40   1079               .0031         282               33410
41   1323               .0028
42   1659               .0025
43   2143               .0022
44   2593               .0020
45   3348               .00176
46   4207               .00157
47   5291               .00140

************************************************************************
For winding Tesla secondary coils the general consensus is to use
number 22 AWG, or larger diameter, double Formvar Magnet wire. Often
surplus partial spools of odd wire sizes are found, so I took time to
post a more complete chart of AWG numbers and fractional diameters
than is usually available.  All information above is approximate
despite the decimal places. Wire diameter, turns per inch, resistance,
feet per pound, etc. all vary slightly from one manufacturer to another.
Insulation thicknesses will vary depending upon type and the supplier.
Turns per inch will also vary with the quality of the winding. In
practice, Tesla coil windings are not perfect (nor do they need to be)
so expect some slight variations from the specification table above.

Richard Quick