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MK-1
Low RPM Single Phase DC Generator
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MK-1
Low RPM Single Phase DC Generator

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14030901
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SANJAY DOCTOR
MIKROFIELDS RESEARCH UNIT
131, Silver Beach Apts., Suryavanshi Hall Lane, Off Savarkar Marg, MUMBAI 400028.
Phone: 9892000857. Email:mikrofields@gmail.com
Website: http://sites.google.com/site/mikrofields
MK1 – Low RPM Single Phase DC Generator

MK1 is a stand-alone Low RPM generator

producing 3-phase AC current. It is rectified to
supply single phase DC. Shown here in test at the
workbench driven by an electric motor.

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MK1 – Low RPM Single Phase DC Generator

Both sides of the generator have 12 stator coils in a radial layout. They are
wired in 3 groups to provide 3 phase AC current. Colour coding is done in
Red, Blue and Yellow. Black coiled wires connect corresponding stator coil set
on each disc to complete the circuit.

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MK1 – Low RPM Single Phase DC Generator

Strontium ferrite magnets provide a strong magnetic field to allow current

generation at low RPM.

Cut into 32 wedges, they rotate between the stator coils. As they rotate,
the strong magnetic field creates a current in each set.

12 wires bring the AC current into the

rectifier panel where each current is
rectified through a rectifier bridge. The
positive (red) and the negative (black)
are grouped respectively to produce the
single-phase DC supply.

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MK1 – Low RPM Single Phase DC Generator

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MK1
Technical Overview

The Generator is based on the design of Alfred T. Forbes, engineer and

inventor, in New Zealand. Improvisation and modifications were made to
create the first prototype model – MK1.

It is a low rpm, low voltage, 3-phase permanent magnet alternator with

internal rectifier diodes to supply direct current.

The design objective was to create a low RPM generator. Renewable energy
applications like wind, water turbines and steam engines have speeds in the
100 – 800 RPM range. Commercial alternators have speeds above 2000 RPM.
Coupling these together requires expensive high ratio gearing or a maze of
belts and pulleys, which are not energy efficient and require high
maintenance.

Strontium Ferrite Magnets are placed in 32 wedges on a rotating disc (rotor)

made of industrial grade electro-mechanical laminate. The power of these
magnets is greater than conventional metal magnets. The ‘long throw’
capability allows for larger air gaps and with higher construction tolerance
enabling an amateur craftsman to assemble the generator.

12 sets of stator coils are placed radially on either side of the rotor. The
north-south direction of magnetism in each magnet is opposite to the ones
next to it. As the rotor turns, the stator coils are caused to be magnetised
first in one direction and then in the other. This generates alternating
electricity as the rotor turns.

The stator coils are grouped into 3 phases (of 4 coils each). At any point,
only 4 pairs of the coils are being covered with 4 magnets while the
remaining 8 magnets are just passing away or coming to the stator coils. This
eliminates the ‘clogging effect’, which would immobilise the magnets and
make it impossible to start again.

The output of each coil is separately passed through rectifier diodes to

produce a DC output, which are then connected in parallel to produce the
final supply.

Team:

Sanjay Doctor.................Design Manager

(Late) KG Kodolikar........Engineer
Shivsagar Singh ..............Technician

Development phase: 1999 – 2009.

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MK1 – Low RPM Single Phase DC Generator

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Production

The MK1 can be manufactured in an workshop with basic tools and a

workbench. It is our aim that the production take place in a rural setting and
that a group of artisans trained as technicians. A cluster of cottage
industries and home industries with a Service Centre as a hub can create an
ecosystem to create an assembly line, which works in a batch-processing
mode.

Casting, lathe operations and industrial coating are the only capital and skill
intensive process which can be outsourced within the ecosystem to specialist
workshops. However in a later evolution, the lathe operations should be in-
house to save costs and develop in-house skills for other production lines.

It is also possible that a technical school function with the unit to create
opportunities for the marginalised, like poor youth, the landless and women,
to learn technical skills and take their rightful place in a rapidly industrialised
rural economy.

Applications

The dynamo can be used with any motive power unit, which works at low
RPM. Biogas engines, biomass gasifiers, wind and water turbines are all
possible sources.

It is proposed that the compressed biogas be used to drive an engine

coupled to the dynamo.
1. Use of a small HP engine requiring less fuel at any point of time
2. Use of catalytic convertors in the exhaust to reduce CO emissions.
Power is produced just-in-time rather than stored in expensive battery
systems. A pressurised Biogas holding tank would store the gas supplied in a
steady stream. The charge controller would distribute power to the actual
load and send the surplus power to the battery bank system used as a
backup. (Source: Alfred Forbes, Inventor)

Rated output (Watts) Volts (DC) Amperes (DC) RPM (at rated output)
The rated power
1008 36 28 740
output of the 896 32 28 673
dynamo as per 784 28 28 597
original design are: 672 24 28 523
560 20 28 450
448 16 28 376
392 14 28 338
336 12 28 301

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MK1 – Low RPM Single Phase DC Generator

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MIKRO

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The philosophy of ‘Mikro’ has evolved from the ideology of Gandhian thought.
It calls for the empowerment of the human being through technology which

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works at a micro level of the household to allow value added production to
meet the basic and aspirational needs of the family.

Inspired by ‘Unto the Last’, it calls for freedom of the household from
monolithic centralised means of production, empowerment to choose the
technology of choice based on the local environment and a bias for the local
economy.

Mikrofields stands for principles of independence and freedom,

accessible technology for the homestead,
and decentralised stand-alone micro power production.
Sanjay Doctor, founder and inventor of MIKROFIELDS RESEARCH UNIT has
been pursuing his interest in sustainable development since 1994. He co-
founded with his wife, Architect Harita, SAT Research and Consultancy (P)
Ltd to pursue applied research and development in organic farming,
ecological housing and appropriate technology. They toured rural India
extensively, training farmers in biodynamic farming and rural technologies.
The company was dissolved in 2003. Subsequently MRU has been founded in
2008 to pursue the ‘Mikro’ agenda.

Above: Ho Chi Minh Cycle trailer

Left: Water flowforms
Below: Biodynamic Agriculture
Planting Calendar

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MK1 – Low RPM Single Phase DC Generator

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THE DEVELOPMENT MATRIX

Based on the research of the past decade, a holistic integrated framework for
planning and program execution is offered for developmental work. At a
macro-level it divides the framework into 4 quadrants with a total of 10
streams.
QUADRANT A QUADRANT B QUADRANT C QUADRANT D
NATURE BUILT KNOWLEDGE SOCIAL
ENVIRONMENT INTERFACE

1 3 Shelter 6 Education
9 Culture
Biodiversity
4 Water and
7 Livelihoods
Sanitation
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10 Gaia
Agriculture 5 Energy 8 Health

LEVEL DESCRIPTORS

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FUTURE RESEARCH AND DEVELOPMENT

1. Control Panel for Home Solar PV

system using Phase Width
Modulation (PWM) charging.

2. Development of under 100W

stand-alone electric generators
for micro windmills with vertical
axis blades.

Inspiration: Aeroturbine by Dr Bill Becker

3. Biogas plant with external

rotating drum and pressurised
storage silo.