Power Efficiency

Guide

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 DISCLAIMER:

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 Additional information

We are not professional writers or photographers and didn’t always have opportunity to
document or photograph every step of development. Therefore, please take the level of
engineer/electrical experience required to build a Power Efficiency Generator very seriously as we are
giving these to you under this premise. You will discover the advanced level of knowledge of
mechanical/electrical processes needed quickly enough. The correct construction of the Power
Efficiency Generator requires patience and careful thought. We made several mistakes in development
and have given here the steps that were successful. You will probably still make mistakes – and these
will be your greatest learning opportunities as you gain more knowledge about this type of energy.

Before beginning to build, consider how much you would like to outsource to one of the
cottage industry community units (CICUs) near you! In the US we recommend Polaris for the steel
stator/rotor construction, and Torelco for toroidal winding. As FTW continues to roll out the
distribution plan, and more connections across the world are made, we think CICUs will be
commonplace and hence, Power Efficiency Generator parts accessible (many people will be making
them!)

When website URLs were available we provided links for the person reading this online. You
may certainly use your own sources for materials but it is imperative you do not alter the
instructions/parts herein if you are building a Power Efficiency Generator. (We know with increased
knowledge you will discover many applications for this technology.) When photographs can be shown
to help you visualize a process, they will be provided. Please remember, we are not professional
manual writers. What we offer you here is our gift to humanity – but it comes with great responsibility.
Learn as much as you can, use discernment and wisdom, share freely, and you will be privileged to
know the secrets of energy creation from the quantum field.

WARNING! We are not responsible for anything in these plans; you build at your own risk.

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1.

Human civilization has started realizing how much harm they have already
caused to the environment, not to mention the costs involved; and when it comes to take
a stand against these environmental problems, the focus shifts to the use of alternative
energy sources. Have you ever wondered what Alternative Energy Sources are? And
why are they supposed to help us sustain? Alternative sources of energy are the ones
which do not cause any undesirable consequences to the environment, are renewable
and are free!

Alternative energy sources can be implemented for houses, for cars, factories and
any other facility you can imagine. Scientists around the world are researching on
developing and discovering new Alternative Energy Sources so that the growing energy
needs of human population can be met more easily, safely and efficiently.

The Power Efficiency Guide does exactly that. It uses one of the basic materials
in nature to convert its power into clean, usable energy. It has been around for
thousands of years and its properties haven’t changed. It’s the magnet.

What are Alternative Energy Sources?

Alternative energy encompasses all those things that do not consume fossil fuel.
They are widely available and environment friendly. They cause little or almost
no pollution. There have been several alternative energy projects running in various
countries to reduce our dependence on traditional fossil fuels. There are many
impressive options that you can take into consideration. Here in you will learn more
about alternative energy sources that you can take into consideration.

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 Solar energy

Solar is the first energy source in

the world. It was in use much earlier
before humans even learn how to light
a fire. Many living things are
dependent on solar energy from plants,
aquatic life and the animals. The solar
is mostly used in generating light and
heat. The solar energy coming down to
the planet is affected by the orbital path of the sun and its variations within the galaxy.
In addition, it is affected by activity taking place in space and on the sun. It was this
energy that is believed to have been responsible for the breaking of ice during the ice
age, which creates the separation of lands and sea.

Solar energy is one the alternative energy source that is used most widely across
the globe. About 70% of the sunlight gets reflected back into the space and we have
only 30% of sunlight to meet up our energy demands. While solar energy is used for
producing solar energy, it is also used for drying clothes, used by plants during the
process of photosynthesis and also used by human beings during winter seasons to make
their body temperature warm. Solar energy can be extracted either by Solar Thermal or
using Photovoltaic (PV) Cells. Learn more about these methods here.

There are two kinds of solar energy the active solar energy and the passive solar
energy. Passive solar energy basically uses duration, position and sun’s rays intensity to
its advantage in heating a particular area. It also uses it to induce airflow from an area to
the next. Active solar energy uses electrical technology and mechanical technology like
collection panels in capturing, converting and
storing of energy for future use.

Solar energy does not create any

pollution and is widely used by many
countries. It is renewable source of power
since sun will continue to produce sunlight all
the years. Solar panels, which are required to
harness this energy can be used for long time
and require little or no maintenance. Solar
energy proves to be ineffective in colder regions which don’t receive good sunlight. It

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cannot be used during night and not all the light from sun can be trapped by solar
panels. Solar energy advantages are much more than its disadvantages which make it as
a viable source of producing alternative energy.

Wind Energy

This is one of the energy sources that have been in use for a very long time and
for centuries. It was used in powering sailing ships, which made it possible for explorers
to sail around their
trade routes in distant
lands. A single
windmill can power
the crop irrigation,
and the family energy
needs, water pumping
and electric lights.
However, in the
present time there are
several windmills that
are used to generate
required energy
mostly for industrial
uses. Many of the
wind turbines can capture much power all at once before feeding it to the power grid.
This is commonly know as wind farms and has been in use for many years all round the
world. It is only the United States that is going slow in terms of accepting this
alternative energy source.

Wind power is renewable source of energy and reduces our alliance on foreign
countries for supply of oil and gas. It does not cause any air pollution and have created
several jobs in last few decades. Advancement in technologies has brought down the
cost of setting up wind power plant. Wind energy can only be used in areas which
experience high winds which mean that it cannot be used as a source to extract energy
anywhere on earth. They sometimes create noise disturbances and cannot be used near
residential areas. These disadvantages have made the use of wind energy to particular
regions only.

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 Geothermal Energy

‘Geo’ means Earth and ‘thermal’ means energy. Geothermal energy means
energy drawn or harnessed from beneath the earth. It is completely clean and renewable.
Geothermal energy has been in used since last several years. The earth contains a
molten rock called magma. Heat is continuously produced from there. The temperature
increases about 3 degrees Celsius, for every 100 meters you go below ground. Below,
10,000 meters the
temperature is so high, that
it can be used to boil water.
Water makes its way deep
inside the earth and hot
rock boils that water. The
boiling water then
produces steam which is
captured by geothermal
heat pumps. The steam
turns the turbines which in
turn activates generators.

Geothermal energy can be found anywhere on the earth. Most countries tap this
energy to generate electricity, using thermal mass flowmeters, and power millions of
homes. The areas which have high underground temperatures are the ones which are the
ones which are prone to earthquakes and volcanoes. The United States produces more
Geothermal electricity than any other country in the world. Most hot water geothermal
reservoirs are located in the western states, Alaska, and Hawaii. Geothermal energy is
totally renewable as earth will continue to produce heat as long as we are all are here. If
these resources are tapped and are utilized effectively, they can provide solution to the
world’s power problems.

Geothermal energy produces

no pollution, reduces our alliance on
fossil fuels. It also results in
significant cost savings as no fuel is
required to harness energy from
beneath the earth. These advantages

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make geothermal energy as one the
best alternative energy source. But, geothermal has its downsides too. It is suitable to
particular region and cannot be harnessed everywhere. The earth may release some
harmful gases while releasing the heat which may prove adverse from mankind. Also,
the areas where this energy is harnessed are prone to earthquakes and volcanoes. Apart
from that, setting up of geothermal power stations requires huge installation cost. Here
are some pros and cons of geothermal energy.

Biomass Energy

This is the process by which an alternative energy is generated through

conversion of biological materials and wastes into forms that can be used as energy
sources for heating, power generation and
transportation. Those carbon based substances
or materials converted over a long period of
time to fossil fuels are not regarded as biomass.
However, in their original state they are
regarded as biomass. This is because of the
separation of the carbon they previously
contained from the carbon cycle. This makes
them figure differently affecting carbon dioxide
levels in air.

Biomass energy has been around since ancient times when people use to burn
wood or coal to heat their homes or prepare food. Wood still remains the most common
source to produce biomass energy. Apart from wood, the other products that are used to
create biomass energy include crops, plants, landfills, municipal and industrial waste,
trees and agricultural waste.

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 Biomass is renewable source of energy as we would be able to produce it as long
as crops, plants and waste exist. It does not create any greenhouse gases and is can be
easily extracted through the process of combustion.

Another advantage of biomass is

that it helps to reduce landfills. Biomass
is comparatively ineffective as compared
to fossil fuels. They release methane
gases which can be harmful to the
environment. Read more about the
advantages and disadvantages of
biomass here.

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 Ocean Energy

The earth promises many

power sources. Just like the
geothermal and solar energy,
which have long been used in
heating homes and lighting as
well when harnessed. Even in
the last century these forms of
energy was in use. Due to
massive size of oceans, this
energy can be used on much
wider scale than other
alternative sources of energy.
The waves produced by the
ocean and tides that hit the sea shore has enormous potential in them. If they are
harnessed with full capacity they can go a long way in reducing world’s energy
problems. There are 3 ways i.e. Tidal energy, Wave energy and Ocean thermal energy
conversion (OTEC) via which ocean energy can be harnessed.

Tidal power basically involves using kinetic energy from the incoming and
outgoing tides. The difference in high tides and low tides are also important in this
respect. There is a lot of energy that can be harnessed from waves for use. It is another
form of hydropower. The rise and fall of ocean tides are captured by tidal energy
generators which turn turbines. The
movement of turbines is responsible
for producing electricity. In short, tidal
energy generator captures the kinetic
motion of the tides and converts them
into electrical energy. The main
advantage of tidal energy is that it is
completely renewable and are much
more predictable than wave energy.
Learn more about the tidal
energy here.

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 Hydrogen Energy

Hydrogen is the most abundant element available on earth but it is rarely alone.
Even water contains two third of hydrogen. It is usually available with other elements
and have to separated before we can make use of it. Hydrogen has tremendous potential
and can be used to power up homes, vehicles and even space rockets. It takes a lot of
energy to separate hydrogen from other elements and therefore it proves to quite
expensive to extract it. Take a close look at hydrogen energy and see how it works.

The main benefit of hydrogen energy is that it is clean source of fuel and does not
leave any waste elements behind except water. There are no harmful emissions and is
environment friendly. It is completely renewable and can be produced over and over
again on demand. Hydrogen can also be used to make bombs like the ones used by
America on Hiroshima and Nagasaki which makes it highly inflammable. Dependency
on fossil fuels still remains as we need them to extract hydrogen from other elements.
Also, it is quite expensive to produce and store.

Hydro Energy

Solar energy is produced by sun and wind energy is produced by moving of

winds. The heat caused by sun drives the wind. The movement of winds is then
captured by wind turbines. Both wind and sun cause water to evaporate. The water
vapor then turns into rain or snow and flows down to sea or oceans through rivers or
streams. The energy of the moving water can then be captured and called
as hydroelectric power. Hydroelectric power stations capture the kinetic energy of
moving water and give
mechanical energy to
turbines. The moving
turbines then convert
mechanical energy into
electrical energy
through generators.
Dams around the world
have been built for this
purpose only.
Hydropower is the
largest producer of alternative energy in the world.

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 There are different types of hydropower plants. The selection of hydropower
plant depends on many volume and flow of water. Hydropower is renewable, constant,
predictable and controllable
source of energy. They emit
no greenhouse gases and are
environment friendly. On the
negative side, they may
cause adverse effect on
aquatic life, reduce flow of
water which may affect
agriculture, require huge
costs to build and may cause
havoc if they get breakdown.

These are some of the alternative energy sources that can be taken into
consideration when planning your energy production and usage. However, they are
either too expensive, too complicated to build, too dangerous to use, or your
geographical position does not favour one or more of them.

However, one of the most overlooked solutions to generate energy is magnets.

Other sources of energy have been used but, with the inevitable increase in the demand
on the world's natural resources, human kind may turn to this unique source of power.

What is a Magnet?

The general definition of a magnet is “An object made of certain materials which
create a magnetic field”

However, the word “magnet” was first used by the Greeks as early as 600 B.C.
for describing a mysterious stone that attracted iron and other pieces of the same
material? According to one Greek legend, the name magnet was taken from the
shepherd Magnets who discovered the magnetic stone by accident when his stuff was
mysteriously attracted to the force of the stone. Another, and perhaps more believable,
theory says that the word magnet came from a city in Asia Minor, called Magnesia,
where many of these mysterious magnetic stones were found.

During the Middle Ages, this stone became known as lodestone, which is the

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magnetic form of magnetite. Today, magnets are available in all sorts of shapes
including discs, rings, blocks, rectangles, arcs, rods, and bars. They are made out of
materials such as ceramic (strontium ferrite), alnico (aluminium, nickel, and cobalt),
rare earth (samarium cobalt and neodymium) and flexible, rubber-like material.

But what is a magnet?

A magnet is an object made of certain materials which create a magnetic field.

Magnets are objects that have a north and south pole at opposite ends. A magnet
contains electrons that have both uneven orbits and uneven spins. Those magnetic atoms
are aligned in nice straight rows inside each domain. And those domains are also lined
up all in the same direction. And only with ALL of these conditions satisfied does this
piece of metal become a magnet. Don't worry if this doesn't make sense -- we'll break it
down over the course of this lesson.

Every magnet has at least one North Pole and one South Pole. By convention, we
say that the magnetic field lines leave the north end of a magnet and enter the south end
of a magnet. This is an example of a magnetic dipole (“di” means two, thus two poles).
If you take a bar magnet and break it into two pieces, each piece will again have a north
pole and a south pole. If you take one of those pieces and break it into two, each of the
smaller pieces will have a north pole and a south pole. No matter how small the pieces
of the magnet become, each piece will have a north pole and a south pole. It has not
been shown to be possible to end up with a single north pole or a single south pole
which is a monopole (“mono” means one or single, thus one pole).

All magnets are made of a group of metals called the ferromagnetic metals. These
are metals such as nickel and iron. Each of these metals have the special property of
being able to be magnetized uniformly. When we ask how a magnet works we are
simply asking how the object we call a magnet exerts it’s magnetic field. The answer is
actually quite interesting.

In every material there are several small magnetic fields called domains. Most of
the times these domains are independent of each other and face different directions.
However, a strong magnetic field can arrange the domains of any ferromagnetic metal
so that they align to make a larger and stronger magnetic field. This is how most
magnets are made.

The major difference among magnets is whether they are permanent or

temporary. Temporary magnets lose their larger magnetic field over time as the domains
return to their original positions. The most common way that magnets are produced is
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by heating them to their Curie temperature or beyond. The Curie temperature is the
temperature at which a ferromagnetic metals gains magnetic properties. Heating a
ferromagnetic material to its given temperature will make it magnetic for a while. While
heating it beyond this point can make the magnetism permanent. Ferromagnetic
materials can also be categorized into soft and hard metals. Soft metals lose their
magnetic field over time after being magnetized while hard metals are likely candidates
for becoming permanent magnets.

Not all magnets are manmade. Some magnets occur naturally in nature such as
lodestone. This mineral was used in ancient times to make the first compasses.
However, magnets have other uses. With the discovery of the relation between
magnetism and electricity, magnets are now a major part of every electric motor and
turbine in existence. Magnets have also been used in storing computer data. There is
now a type of drive called a solid state drive that allows data to still be saved more
efficiently on computers.

Not only do the shape and material of magnets vary, so do their applications. At
many companies, magnets are used for lifting, holding, separating, retrieving, sensing,
and material handling. You can find magnets in a car and around your house. Magnets
are used in the home to organize tools or kitchen utensils and can be found in doorbells,
loudspeakers, microwaves, and televisions. Business offices and schools use magnetic
planning boards to display schedules and charts.

Magnets are also used in a compass to guide people if they are lost. In fact, the
compass was probably the first important magnetic device discovered. Around the 12th
century, someone noticed that when allowed free movement, a magnet always points in
the same north/south direction. This discovery helped mariners who often had trouble
navigating when the clouds covered the sun or stars.

But the use of the magnets for this device will revolutionize the entire energy
industry.

What is an electromagnet?

An electromagnet is a magnet that runs on electricity. Unlike a permanent

magnet, the strength of an electromagnet can easily be changed by changing the amount
of electric current that flows through it. The poles of an electromagnet can even be
reversed by reversing the flow of electricity.

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 An electromagnet works
because an electric current produces a
magnetic field. The magnetic field
produced by an electric current forms
circles around the electric current, as
shown in the diagram below:

Mechanically, an electromagnet
is pretty simple. It consists of a length
of conductive wire, usually copper,
wrapped around a piece of metal. A
current is introduced, either from a battery or another source of electricity, and flows
through the wire. This creates a magnetic field around the coiled wire, magnetizing the
metal as if it were a permanent magnet. Electromagnets are useful because you can turn
the magnet on and off by completing or interrupting the circuit, respectively.

Before we go too much farther, we should discuss how electromagnets differ

from your run-of-the-mill "permanent" magnets. As you know, magnets have two poles,
"north" and "south," and attract things made of steel, iron or some combination thereof.
Like poles repel and opposites. For example, if you have two bar magnets with their
ends marked "north" and "south," the north end of one magnet will attract the south end
of the other. On the other hand, the north end of one magnet will repel the north end of
the other (and similarly, south will repel south). An electromagnet is the same way,
except it is "temporary" - the magnetic field only exists when electric current is flowing.

The doorbell is a good example of how

electromagnets can be used in applications where
permanent magnets just wouldn’t make any sense.
When a guest pushes the button on your front door, the
electronic circuitry inside the door bell closes an
electrical loop, meaning the circuit is completed and
“turned on.” The closed circuit allows electricity to
flow, creating a magnetic field and causing the clapper
to become magnetized. The hardware of most
doorbells consist of a metal bell and metal clapper that,
when the magnetic charges causes them to clang
together, you hear the chime inside and you can
answer the door. The bell rings, the guest releases the button, the circuit opens and the
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doorbell stops its infernal ringing. This on-demand magnetism is what makes the
electromagnet so useful.

Permanent Magnets and Electromagnets: What are the Differences?

A permanent magnet is an object made from a material that is magnetized and

creates its own persistent magnetic field. As the name suggests, a permanent magnet is
'permanent'. This means that it always has a magnetic field and will display a magnetic
behavior at all times.

An electromagnet is made from a coil of wire which acts as a magnet when an

electric current passes through it. Often an electromagnet is wrapped around a core of
ferromagnetic material like steel, which enhances the magnetic field produced by the
coil.

Permanent Magnet v. Electromagnet: Magnetic Properties

A permanent magnet’s magnetic properties exist when the magnet is

(magnetized). An electromagnetic magnet only displays magnetic properties when an
electric current is applied to it. That is how you can differentiate between the two. The
magnets that you have affixed to your refrigerator are permanent magnets, while
electromagnets are the principle behind AC motors.

Permanent Magnet v. Electromagnet: Magnetic Strength

Permanent magnet strength depends upon the material used in its creation. The
strength of an electromagnet can be adjusted by the amount of electric current allowed
to flow into it. As a result, the same electromagnet can be adjusted for different strength
levels.

Permanent Magnet v. Electromagnet: Loss of Magnetic Properties

If a permanent magnet loses its magnetic properties, as it does by heating to a

(maximum) temperature, it will be rendered useless and its magnetic properties can be
only recovered by re-magnetizing. Contrarily, an electromagnet loses its magnetic
power every time an electric current is removed and becomes magnetic once again
when the electric field is introduced.

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 Permanent Magnet v. Electromagnet: Advantages

The main advantage of a permanent magnet over an electromagnet is that a

permanent magnet does not require a continuous supply of electrical energy to maintain
its magnetic field. However, an electromagnet’s magnetic field can be rapidly
manipulated over a wide range by controlling the amount of electric current supplied to
the electromagnet.

The Power Efficiency Guide uses this principles and multiplies the energy the
magnets supply, eventually offering enough energy to power household appliances.

The most recent and life changing discovery is the Neodymium Magnet

A neodymium magnet (also known as NdFeB, NIB or Neo magnet), the most
widely used type of rare-earth magnet, is a permanent magnet made from
an alloy of neodymium, iron and boron to form the Nd2Fe14B tetragonal crystalline
structure. Developed in 1982 by General Motors and Sumitomo Special Metals,
neodymium magnets are the strongest type of permanent magnet commercially
available. They have replaced other types of magnets in the many applications in
modern products that require strong permanent magnets, such as motors
in cordless tools, hard disk drives and magnetic fasteners.

Description

Neodymium is a metal which is ferromagnetic (more specifically it

shows antiferromagnetic properties), meaning that like iron it can be magnetized to
become a magnet, but its Curie temperature (the temperature above which its
ferromagnetism disappears) is 19 K (−254 °C), so in pure form its magnetism only
appears at extremely low temperatures.[4] However, compounds of neodymium
with transition metals such as iron can have Curie temperatures well above room
temperature, and these are used to make neodymium magnets.

The strength of neodymium magnets is due to several factors.

The tetragonal Nd2Fe14B crystal structure has exceptionally high
uniaxial magnetocrystalline anisotropy (HA ~7 T – magnetic field strength H in units
of A/m versus magnetic moment in A·m2).[5] This means a crystal of the material
preferentially magnetizes along a specific crystal axis, but is very difficult to magnetize
in other directions. Like other magnets, the neodymium magnet alloy is composed
of microcrystalline grains which are aligned in a powerful magnetic field during

17
manufacture so their magnetic axes all point in the same direction. The resistance of the
crystal lattice to turning its direction of magnetization gives the compound a very
high coercivity, or resistance to being demagnetized.

The neodymium atom also can have a large magnetic dipole moment because it
has 7 unpaired electrons in its electron structure[6] as opposed to (on average) 3 in iron.
In a magnet it is the unpaired electrons, aligned so they spin in the same direction,
which generate the magnetic field. This gives the Nd2Fe14B compound a high saturation
magnetization (Js ~1.6 T or 16 kG) and typically 1.3 teslas. Therefore, as the maximum
energy density is proportional to Js2, this magnetic phase has the potential for storing
large amounts of magnetic energy (BHmax ~ 512 kJ/m3 or 64 MG·Oe). This magnetic
energy value is about 18 times greater than "ordinary" magnets by volume. This
property is higher in NdFeB alloys than in samarium cobalt (SmCo) magnets, which
were the first type of rare-earth magnet to be commercialized. In practice, the magnetic
properties of neodymium magnets depend on the alloy composition, microstructure, and
manufacturing technique employed.

History

In 1982, General Motors (GM) and Sumitomo Special Metals discovered the
Nd2Fe14B compound. The research was initially driven by the high raw materials cost
of SmCo permanent magnets, which had been developed earlier. GM focused on the
development of melt-spun nanocrystalline Nd2Fe14B magnets, while Sumitomo
developed full-density sintered Nd2Fe14B magnets.

GM commercialized its inventions of isotropic Neo powder, bonded Neo

magnets, and the related production processes by founding Magnequench in 1986
(Magnequench has since become part of Neo Materials Technology, Inc., which later
merged into Molycorp). The company supplied melt-spun Nd2Fe14B powder to bonded
magnet manufacturers.

The Sumitomo facility became part of the Hitachi Corporation, and currently
manufactures and licenses other companies to produce sintered Nd2Fe14B magnets.
Hitachi holds more than 600 patents covering neodymium magnets.

Chinese manufacturers have become a dominant force in neodymium magnet

production, based on their control of much of the world's sources of rare earth mines.

The United States Department of Energy has identified a need to find substitutes
for rare earth metals in permanent magnet technology, and has begun funding such
research. The Advanced Research Projects Agency-Energy has sponsored a Rare Earth

18
Alternatives in Critical Technologies (REACT) program, to develop alternative
materials. In 2011, ARPA-E awarded 31.6 million dollars to fund Rare-Earth Substitute
projects.[9]

Production

There are two principal neodymium magnet manufacturing methods:

• Classical powder metallurgy or sintered magnet process

• Rapid solidification or bonded magnet process

Sintered Nd-magnets are prepared by the raw materials being melted in a furnace,
cast into a mold and cooled to form ingots. The ingots are pulverized and milled; the
powder is then sintered into dense blocks. The blocks are then heat-treated, cut to shape,
surface treated and magnetized.

In 2015, Nitto Denko Corporation of Japan announced their development of a

new method of sintering neodymium magnet material. The method exploits an
"organic/inorganic hybrid technology" to form a clay-like mixture that can be fashioned
into various shapes for sintering. Most importantly, it is said to be possible to control a
non-uniform orientation of the magnetic field in the sintered material to locally
concentrate the field to, e.g., improve the performance of electric motors. Mass
production is planned for 2017.

As of 2012, 50,000 tons of neodymium magnets are produced officially each year
in China, and 80,000 tons in a "company-by-company" build-up done in 2013. China
produces more than 95% of rare earth elements, and produces about 76% of the world's
total rare-earth magnets.

Bonded Nd-magnets are prepared by melt spinning a thin ribbon of the NdFeB
alloy. The ribbon contains randomly oriented Nd2Fe14B nano-scale grains. This ribbon
is then pulverized into particles, mixed with a polymer, and either compression-
or injection-molded into bonded magnets. Bonded magnets offer less flux intensity
than sintered magnets, but can be net-shape formed into intricately shaped parts, as is
typical with Halbach arrays or arcs, trapezoids and other shapes and assemblies (e.g. Pot
Magnets, Separator Grids, etc.). There are approximately 5,500 tons of Neo bonded
magnets produced each year. In addition, it is possible to hot-press the melt spun
nanocrystalline particles into fully dense isotropic magnets, and then upset-forge or
back-extrude these into high-energy anisotropic magnets.

19
 Properties

Neodymium magnets are graded according to their maximum energy product,

which relates to the magnetic flux output per unit volume. Higher values indicate
stronger magnets and range from N35 up to N52. Letters following the grade indicate
maximum operating temperatures (often the Curie temperature), which range from M
(up to 100 °C) to EH (200 °C).

Hazards

The greater forces exerted by rare-earth magnets create hazards that may not
occur with other types of magnet. Neodymium magnets larger than a few cubic
centimetres are strong enough to cause injuries to body parts pinched between two
magnets, or a magnet and a ferrous metal surface, even causing broken bones.

Magnets that get too near each other can strike each other with enough force to
chip and shatter the brittle material, and the flying chips can cause various injuries,
especially eye injuries. There have even been cases where young children who have
swallowed several magnets have had sections of the digestive tract pinched between two
magnets, causing injury or death. The stronger magnetic fields can be hazardous to
mechanical and electronic devices, as they can erase magnetic media such as floppy
disks and credit cards, and magnetize watches and the shadow masks of CRT type
monitors at a greater distance than other types of magnet.

That is why we recommend extra precaution when building the generator.

1.1 Power Efficiency Guide – Means of operation

The generator is based on the following principles (derived from the Tesla’s
principle): the magnetic field generated by a group of controlled and temporized coils
can set a rotor in motion and this motion can then be used as source for an alternator.
Without going into scientific details, we offer you a product, as simple as it is effective:
a group of diodes generates a magnetic field using a control board.

The magnetic field is transferred to the magnets on a rotor creating rotational

motion, which in turn engages an alternator which produces electricity. In short, these
are the components of our generator, as units.

20
Here’s a diagram of the generator:

The diagram it’s only for one drive coil, and we used in the current project two
drive coils.

1.2 Applications
The Power Efficiency Guide can be used as a power generator (to power a
house), a portable generator (the perfect replacement for the old gasoline/diesel
generators) or it can charge a group of batteries (which were discharged for later use).

1.3 Advantages
This generator is constructed of lightweight but solid materials and it requires
extremely small circuits in size and cost. It is also the perfect choice for a cleaner and
healthier future for our children, since it doesn’t involve any smoke or noise.

The low cost, the light weight, no noise and no pollution make this generator a
strong competitor for any large scale device currently known.

21
2.1 List of tools
a. Fixed isolated screwdrivers set

b. Magnetic head screwdrivers set

c. Wire strip pliers

d. Cutter

e. Scissors

f. Small beaked pliers

g. Normal pliers

h. Drill

i. Drill bits set

j. Adjustable wrench

k. Fixed wrenches

l. Caliper, ruler, protractor

m. Measuring Device

n. Electrical cables of different colors

2.2 List of materials

a. Two-component adhesive

b. Insulating Tape

c. Zip Ties

d. Long bolts for fixing 8-10 pcs

e. Short bolts, filed washers

f. A piece of rubber for electrical isolation

22
g. Marker

h. 500m copper wire for AWG winding

i. Alternator 1 piece

j. Switcher 1 piece

k. Neodymium magnet 12 pcs

l. Axle bearings 12 pcs

m. Hamlin 55140 magnetic sensors 2 pcs

n. Cable lugs

o. Extension cords 8 pcs

p. batteries 12v 1 pcs

q. Control board MMG-041 1 pcs

r. Coils 8 pcs

s. Magnetic core 8 pcs

t. Plexiglass (textolite/wood) cut in different sizes and shapes to sustain various

components

- Cylinder - 3 cm thickness 1 pcs (it will be cut in 6 pcs x 5mm)

- 5 x 5 cm frames (used for supporting the coils) - 8 pcs

- Smooth edges - 2 pcs

- Test board - 6 bulbs connected in series, bulb switch, plug, plug switch, cables

Please notice there are no other connections hidden on the other side.

23
 a. Coil Construction
We will start by winding the copper wire on the plastic pad, leaving one end for
subsequent couplings. At this point, we will make sure that spires to be positioned next
to each other, avoiding blanks.

Tip: To avoid slipping wire, you can fix it with a piece of duct tape.

Make sure the spires are nicely arranged. About 300 spires are needed.

Eventually, the remaining end will be arranged in the opposite edge of the first, for
easier tracking during connection.

You can isolate with duct tape and then the loose ends will be stripped using a cutter.

We will attach cables of different colors (in this case, black for the ending point and
brown for the starting point), then isolate the connections and position them as shown in
the picture for ease of connectivity.

We will then prepare the two-component adhesive that will fix the magnetic core inside
the plastic tube on which we have wound the copper wire. It needs about 15 minutes to
dry. For efficiency, we have already built the other seven coils using the exact same
method.

b. Construction of the rotor

Because we need a support of about 3 cm, we will assemble the six pieces of Plexiglas
used in this case, in one single disc to avoid unnecessary friction.

In the present project, we are using Plexiglas for better visibility, for transparency and in
the end for less weight.

We will utilize a longer bolt in order to have a fixed support and to subsequently tighten
the nut for stiffening and hardening.

For this purpose, we will need the two component adhesive again, to point apply on the
surface of the discs. We will enlarge this surface by rotating the discs, as shown in the
picture.

Caution: Do not prepare a large amount of adhesive because it is likely to harden and

24
become unusable.
We will repeat the process until we have added all discs.

Caution: Do not over tighten the bolt or you’ll crack the Plexiglas (risk disappears if
you use a version of textolite or wood with the specified size).

After fastening and drying (around 15 min) of adhesive, we will remove the rotor from
support.

Then, using a ruler, we’ll draw a diameter as shown in the picture.

Then draw another diameter at 90 degrees. Then, using a protractor, we will halve to 45
degrees the already marked sectors.

Next, we need to fasten the neodymium magnets on the disc we obtained. Because there
have holes, they can be fixed by screwing in wood or textolite. In this case, we will use
the two-component adhesive again.

The magnets will be marked north (N) and fixed with the middle on each axis direction.

In the end, the disc will have the magnets mounted as shown in the image. This requires
drying time, which is why we recommend you stick them one at a time.

c. The supports for coils

These will be fixed as shown in the picture on each of the pieces cut in a square with the
two-component adhesive. It will allow for drying and curing.

Make sure the wires are positioned on one side of the square. The side on which we will
stick the plastic brackets will be the one where we left the cables for subsequent
connections.

We proceed analogously for all coils.

d. Connectors assembly
They will be mounted above the plastic bracket as shown in the picture. The connection
bridges will be placed on the direction of the connectors. Subsequently, the free ends
will be introduced in two of the four couplings. The same coupling rule will be followed
for easy connectivity later.

We’ll do the same for all 8 coils.

25
 a. Rotor assembly
We will use one of the longer bolts as a pin.

Then, we will put one of the bearings and fix it with a bolt. Next, we’ll add another bolt
(which then we can use for disc adjustment) to create the constraining effect. Then we’ll
add a washer...disc, a new washer ... bolt ... and fasten the disc between the two bolts.
Then add the second bearing and fasten it with a bolt.

The disc must run easily without friction on the two bearings.

b. Bracket support assembly

We will now take a Plexiglas side, drill a central hole in which we’ll put the bearing and
small side holes that will ensure fixation.

We will use long bolts with washers and nuts as shown in the image. Don’t over tighten
the bolts, to avoid cracking the material. We will ensure that they are properly tightened
to have the best possible overall reinforcement.

Next, we will introduce the rotor shaft mounted above.

Next to each magnet, we will fix the bracket supports so that the distance from the
center of the coil to the magnet to be 3 mm. Using the caliper to do the measurements,
we will make sure that the distances are correct. In this case, the attachment will be
made using the adhesive again. If you use textolite or wood, you can utilize L-sites,
screws or other fasteners.

You can also mark the support spot for the coils, so you don’t have to repeat the
measurements.

The adhesive’s purpose is to fix the brackets, hardening being achieved with the other
side.

If, when fixing with adhesive, the coils will move, we’ll repeat the measurements after
each fastening. It is the smoothest part of the assembly that requires skill and patience.

After drying, you’ll see the final arrangement of the coils. Our generator is already
beginning to come alive.

26
We now need to add the other side to the assembly. During drying of the adhesive, on
fastening the coils, you can see we have placed 4 bolts into the holes near the central
axis. This side part will be put down easily, inside the holes, without excessive pressure
to prevent damage to the Plexiglas.

Analogous to the first, we will fix the fastening bolts using the washer and nut system.
A spacer under the top side will leave the rotor shaft free. Now stiffen slightly.

Then we mount the switch and fasten small bolts for the alternator.

c. Mounting the control and recovery board

First, we need to determine the place where our board will be located. Then, we’ll mark
the spot and drill the proper holes, pressing slightly not to crack the support.

Also make sure the holes do not pierce the coils, so avoid drilling towards the coils. The
spacing will be done using bolts.

In this case, we will only need 3 bolts, as it is not required to support heavy weight.

We will use fine-tipped pliers for fixing bolts. So this is how we mount the control
board.

d. Coils connection
Two of the eight coils, which are called control coils, will link directly to the control
board and the other will be connected in series.

We are using cables of variable length, so that they reach up the control board.

At the end where we have the board, we will use connectivity lugs. The cables are
plugged into the connector on the coil, according to the color code, as they represent the
extension of the coils’ ends: brown to brown, black to black.

Brown wires will come outside the control board at each end of it.

Control coils are connected directly to the board, each on the control board’s ends, as
shown in the picture.

The coils connected in series will be joined together like this: the remaining pins from
the connectors on the coils are joined to each other with wires of the same color.

We’ll then repeat the procedure, noting that control coils will be "left out" from the

27
series connection.
The end of this series connection will be linked with lugs on the 3, 4 pins of the control
board as shown in the picture.

Care must be taken when pins are connected to the control board, so they do not touch
each other. You can use duct tape to prevent this from happening.

Recap: The control coils that you see here will be directly connected to the pins outside
the MMG-041 board. The remaining coils are connected in series and the end of the
series will also be connected to the control board.

e. Fastening the 55140 Hamlin magnetic sensors

At a distance of about 3 cm from the edge, we will mount the neodymium magnets
(which control the magnetic sensors) on the rotor.

General Summary:

So, on one lateral side we placed the coils. Two of them are control coils, connected to
the pins outside the control board and the rest are connected in series and to pins 3, 4.
On the other side of the plexiglass support we mounted the control board.

After mounting the magnets on the axles, we have also placed on one side of the rotor,
the magnets necessary for the magnetic impulse, controlled by the board, on about 3 cm
from the edge.

The other plexiglass support contains the switch and the alternator.

The pins made of short bolts are for:

- Powering the 12V battery – the left image

- Output of the alternator, where we get the 110V – the right image

f. Generator assembly
It is time for the finishing touch and connection of the assemblies obtained so far.

We will use two batteries as spacers, not to disturb the central axis of the rotor.

First fix the rotor position.

Then cover with the other support, slightly tightening the entire assembly with the bolts.

From the 12V pins of the battery, we connect to the motherboard in pins 6, 7. The
positive uses the red color and the negative uses the blue color.
28
Following is the coupling of magnetic sensors with adhesive. We will check both the
distance of the cables that reach the control board, as well as their location from the
magnets mounted on the lateral side of the rotor.

When the magnet passes next to the sensor, you will hear a smooth click.

Later, after drying, the sensors will be connected to the control board.

Meanwhile, we can adjust the rotor shaft and couple the alternator to the switch of the
device.

We'll show you how they are coupled, previously isolating the ends to avoid short
circuits between the pins of the control board. The positive is represented by the green
(with red lug end), and the negative is represented by the black wire (blue lug end).

Therefore we obtained the couplings where we have:

1. Control coils - pins 1, 2 (top-down) and pins 11, 12.

2. Coils in series - pins 3, 4.
3. Magnetic sensor Nr.1 - pins 5, 8.
4. Magnetic sensor No.2 - pins 9, 10.
5. 12v Battery – pins 6, 7.

As we were saying, on the opposite side, we connected the alternator to the switch, and
the switch to the 12V power supply as shown in the image.

The last stage of our project is using zip ties for reinforcing and proper fastening of the
existing cables. We aim to have the best possible ergonomics of the assembly, so that in
the end we can easily distinguish all the building units, connectivity as well as
functionality of the generator without any accidental friction.

We will conduct a brief inspection at the pin connection wires.

And here we are and at the end of our project.

We will mount the 12V battery to the pins indicated on the front panel, respecting the
positive to positive and negative to negative rule.

Also, the test panel (consisting of 6 bulbs and sockets) will be connected at this stage.

We are working with HIGH VOLTAGE, so make sure:

- The switch is off (in this case, down)

29
 - The wiring connections are properly insulated

Interacting with the 110V must be done with extreme caution, as there is risk of electric
shock.

Also avoid touching bolts that connect to 110V, sufficient reason for applying an
insulating layer of duct tape.

The last connections were the 12V battery to the pins on the front panel and the test
panel with 6 bulbs and socket (on which we hooked a measuring device).

Say START. Note that it starts working. After about 5 seconds needed for the rotation
speed to stabilize, we can start the test panel for the 6 bulbs. As you can see, they are
working properly.

Then you can also power the plug using the switch, to certify those 110V of the plug.
Deviation from the 107V display is allowed.

Thank you for joining us.

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