1


put [2]. These machines are composed of two parts - field cir-
cuit (rotor) and the winding circuit (or armature). In the previ-
Archimedean Screw Hy- ous, the magnetic field is produced or supplied, while in the
latter is where the conductor formed into a coil is located and
droelectric Turbine as the the voltage is induced [3]. Generators may have a rotating ar-
mature or a rotating field. In this project's case, the generator

Prime Mover Mechanism is composed of a rotating field and a stationary armature.

of a Single Phase-, 30V-, As electrical engineering students, it is of utmost impor-

tance to apply the concepts taught and learned from the lec-

L. Castuera, Member, IIEE, C. D. de Ocampo, Member, IIEE, I. P. Estuye, Member, IIEE, P. Fresto,
Member, IIEE, and J. Halum, Member, IIEE

tures regarding AC machines, specifically generators. Hereby,

60Hz- AC Generator this project serves as a corroboration of how well the students
understood the lessons.
Abstract—This paper dwelt on the construction and operation
of one AC machine, the generator. The objective of this project is
to design and construct a rotating field AC generator with a rotor The objective of this project is to design and construct a ro-
consisting of permanent magnets as a source of the magnetic tating field AC generator with a rotor consisting of permanent
field, an armature circuit with built-in alligator clips connected to magnets as source of the magnetic field, an armature circuit
its terminals, and water as its prime mover. The machine was de-
with built-in alligator clips connected to its terminals, and wa-
vised with 16 poles, #32 AWG magnetic copper wire, and a stator
with 16 slots, and 500 turns per coil or slot. The group intended ter as its prime mover. The machine is devised with 14 poles,
to build an AC generator with an induced voltage of at least 30 #32 AWG magnetic copper wire, and a stator with16 slots,
Volts (rms) at the rated speed, and a sinusoidal voltage waveform and 500 turns per coil or slot. The group aims to build an AC
having a nominal frequency of 60 Hz plus or minus five (55 to 65 generator with induced voltage of at least 30 V (rms) at the
Hz). By numerous trial and error testing, the group arrived at an rated speed, and sinusoidal voltage waveform having a nomi-
output of _______ electrical frequency and ___ nominal gener-
ated voltage. Hence, using the concepts and formulas expounded
nal frequency of 60 Hz plus or minus 5 (55 to 65 Hz). To
during lectures, the theoretical outputs of the generator are ap- achieve the parameters mentioned, the group used water and
proximately achieved. Archimedean screw as the prime mover and prime mover
mechanism, respectively.
Index Terms—Generator, Archimedean screw, armature, elec-
trical frequency, field circuit, induced voltage, magnetic copper This paper presents the materials used and the procedures
wire, neodymium magnets, rotor, winding circuit. undertaken to create the generator. Computations of the speed
rating and internal voltage generated of the machine, and other
I. INTRODUCTION
references used for the construction of the project are also dis-

A .lternating Current machines (e.g. generators, motors,

and transformers) work under the principle of electro-
magnetism. The concept of electromagnetism that allows these
cussed in the proceeding sections of this paper. Outputs from
the succeeding tests up to the final testing of the machine are
incorporated in this paper.
AC machines to function involves a magnetic field, a conduc-
tor, and an interaction between these two variables [1]. Volt- II. MATERIALS
age in a conductor is induced by the moving magnetic field
With in-depth brainstorming and research, the group came
around the conductor, while magnetic field is produced around up with the configuration and components of the AC genera-
a conductor if an electrical current pass through it. In other AC tor. The detailed procedure in creating the machine, from the
machines’ cases, electromagnetism works by the presence of a prime mover mechanism, rotor, stator, up to its enclosure, are
magnetic field characterized by a current- carrying wire and/or recorded in the following statements.
a moving wire which in turn induces a force and voltage on it,
respectively. A. Materials specifications
To create this project, the materials utilized and their quan-
This paper dwelt on the construction and operation of one tities/measurements are the following:
AC machine, the generator. A generator or AC generator is an 1) Enclosure of the prime mover mechanism: The enclo-
AC machine that, by the principle of electromagnetism and sure of the prime mover was made using three pieces of
electromagnetic induction, converts mechanical energy from wood with dimensions 0.9144m by 0.3048m by
an external source into alternating electrical energy as its out- 0.3048m. The wooden frames were connected and fas-
tened, as in Fig. 39, using screws.

 2

2) Prime mover mechanism (Archimedes Screw): In addi- helical shape. The helically formed PVC pipes were then at-
tion to the wood and metal components, three canisters tached to the hub made of recycled plastic cylindrical contain-
were aligned, and skewed or supported by a threaded ers. The ends of the body were fitted with bolts in its center to
shaft that passed through the center of each container. enable it to hold unto the threaded rod when rotation is later
In the prime mover mechanism’s blades, flattened introduced.
sheets of Polyvinyl Chloride pipes were used, that were The body frame or the enclosure of the generator, made of
securely attached by an epoxy adhesive, specifically the wood, was designed to protect and hold the Archimedes
All-Purpose Pioneer Epoxy. In addition, one 0.02 m 3 screw, the rotor and the stator into place. Bearings were in-
Polyethylene terephthalate (PET) container was utilized stalled to the wooden frame holding the ends of the threaded
to contain the water and as the case back of screw (see rod to permit near frictionless rotation and improve efficiency.
Fig. 34). The PET water container was cut into half and fastened at the
bottom part of the design. Further, to guide the water flowing
3) Rotor: For the rotor’s main component, the group used a inside the prime mover mechanism and to protect the blades
recycled rotor from an old stand fan ( Fig. 31.). To com- from possible exterior damaging materials by blocking it. A
plete the construction of the rotor, and achieve a rotating crank was also added for the sole purpose of simulating the
magnetic field, fourteen pieces of (N52 - graded) prime mover’s RPM.
Neodymium magnets (see Fig. 20.) were attached on the The fitting of the stator or armature was built according to
cylindrical rotor. the size and design of the salvaged rotor. The stator is com-
posed of PVC pipe as the holder of the slots, glue sticks as the
4) Stator: The stator design is composed of five essential slots, and magnetic wire as the armature coil turns. The length
materials: magnetic copper wires (see Fig. 1.), glue sticks, of the glue sticks, used as the slots, was estimated according to
screws, PVC pipe, and an Arduino-based winding turn the available space between the rotor and the PVC pipe.
counter (see Fig. 27.). Approximately two hundred fifty The windings per slot are arranged in a specific direction
(250) grams of magnetic copper wires were used to pro- such that the all are winded towards the rotor but in an alter-
duce sixteen 500 turns windings. A PVC pipe with a nate manner – counter clockwise and clockwise. This pattern
height of 32mm, an outside diameter of 107mm, and in- continues in a cycle until all 16 slots are filled (See Fig. 46. for
side diameter of 103mm was used as the support for the reference). The slots are then attached inside the PVC pipe in-
coils. For the coils to remain intact, a total of five glue serted into a larger pipe for the purpose of making the project
sticks - two per pole, were placed in the PVC pipe. neat.
Lastly, an Arduino-based winding turn counter (see Fig. (See Appendix B to view the documentations for the procedures.)
27) was designed to record and count the number of turns
of the copper winding. C. Design parameters
(See Appendix A to view other materials utilized in this project.)
Prior the final testing of the machine, the mechanical and
electrical parameters needed for its operation were computed.
B. Procedures for building the generator To achieve the desired frequency and generated voltage of this
The detailed procedure for creating the generator, starting project, the group used the formulas derived during lectures.
from the prime mover, rotor, stator, to enclosure of the prime The following are the formulas utilized:
mover mechanism, are stated in the following statements. Be-
low are the step-wise processes for the construction of the P nm
project. f e= , (1)
The end part of the rotor’s rod was re-threaded to allow the 120
bolts and washer to latch when installed together with the
bearings at the prime mover. Fourteen (14) magnets were at- where: f e is the electrical frequency (Hz), P is the number of
tached at the lateral area of the cylindrical rotor using an in- poles, and n m is the angular velocity (rpm);
stant glue. The magnets were arranged in alternating polarity
order such that the initial magnet’s polarity is north pole. The E a=4.44 N c ϕ f e=4.44 N c B m A f e ,
second magnet was then glued the opposite manner - south
(2)
pole being its polarity. This arrangement of the magnets to the
rotor was performed repeatedly until the 14th magnet.
As the prime mover mechanism of the generator, the group where: E ais the voltage generated, N c is the number of turns
used the Archimedean screw model (see Fig. 30.), which was or conductors, ϕ is the magnetic flux (Wb), Bm is the maxi-
believed as an ancient machine used to pump water and later mum magnetic flux density (T), A is the cross-sectional area
utilized as hydro turbines for electricity generation [4], [5],
of the magnet (m2), and f e is the electrical frequency (Hz).
[6]. The screw has an axis or shaft with helical blades, lying in
a channel with a semi-circular or even closed circular cross- In order to arrive at a frequency value of 60 Hz, and with 14
section [7], [8]. For the blades of the screw used in the project, magnets attached on the rotor, thus, 14 poles, the computed or
recycled PVC pipes were used. The PVC pipes, normally stiff, rated speed requirement of the machine is 514.2857 rpm or ap-
were exposed to a blow torch to restructure it into PVC sheets, proximately 515 rpm. Using (1), the computation for the fre-
which were then cut into a circular shape, and formed into a quency is as follows:
 3

P nm D. Performance (pre- and post-final testing)

f e=
120 Before the final testing was conducted, the group performed
four tests to record the output angular speed and five tests to
120 f e measure the voltage generated of the generator. The measure-
n m= ment of the generated angular velocity was carried out in Sor-
P
sogon State University – Baribag Campus, along the river be-
side the campus. Using a tachometer, a device used to measure
120 (60 Hz) the average rotation speed of a shaft or disk, the group
n m=
14 poles recorded 120 rpm, 270 rpm, 570 rpm, and ___ in the first, sec-
ond, third and fourth testing, respectively. On the other hand,
n m=514.2857143 rpm. after multiple re-arrangements of the magnetic wire windings,
the group recorded that the AC machine can generate voltages
Therefore, for the generator to produce 60 Hz, the rated speed with values: 0.3 V during the first test, 1 V on the second trial,
requirement of the machine is 514.2857 rpm or approximately and 30 V on the last three tests.
515 rpm. In the case of the induced voltage of the generator, although
So as to achieve an induced voltage of 30V, by the use the theoretical value was reached, its output frequency ex-
Adams Magnetic Products Magnetic Field Calculator, the type ceeded the desired value; instead of 60 Hz, the machine pro-
of magnet (NdFeb 52) used in this project has a flux density of duced an average of 140Hz. To compensate for the excessive
1479 Gauss or an equivalent 0.1479 Tesla [9]. Since the mag- frequency, the group added a screw in each slot – between the
nets have dimensions of 10mm by 25mm, the cross-sectional support (glue sticks) inserted inside the windings. Following
area computed is 250mm2 or 0.00025m2. Substituting the val- the corrections, both the desired electrical frequency and gen-
ues of the theoretical voltage generated, electrical frequency, erated voltage of the machine – 60 Hz and 30 V, respectively,
magnetic flux density, and cross-sectional area of the magnet, were satisfied.
the total number of turns is computed, using (2), to be equal to
3045.641991 turns. III. APPENDIX
E a=4.44 N c Bm A f e
TABLE I.
Parameter and Quantity Used in the Generator
Ea Parameter Value/Quantity
N c=
4.44 B m A f e Voltage 30 V
Frequency 60 Hz
30 V Slots 16
N c= 2 Magnet type 14 pieces Neodymium -
4.44 (0.1479 T )(0.00025 m )(60 Hz) N52 NdFeB magnets
Magnets/poles 14
N c =3045.641991 turns Magnet width 10 mm
Magnet thickness 5 mm
3045.641991 turns Magnet height 25 mm
N c= Magnetic flux density 1479 Gauss = 0.1479
16 slots
Tesla
N c =1 90.352624438 turns per slot . Magnetic copper wire #32 AWG
Turns per slot 500
Total number of turns 8000
Therefore, with 16 slots and a total number of turns equal to
3045.641991 turns, the turns per slot is 190.352624438 or ap- APPENDIX A
proximately 190. Materials Used
Since the number of slots in the armature is 16, having a 7:8
ratio of the number of poles to the number of slots, the distri-
bution of turns per slot is 190. Considering the losses contrib-
uted by factors identified by the group, such as the distance of
the slots with respect to the rotor, type of magnet used, gap be-
tween the slots, manner in which the magnetic wires are
winded, etc., the group conducted numerous trial and error
tests. Furthermore, to meet the expected outputs of the genera-
tor - 60Hz frequency and 30V generated voltage, instead of
Fig. 1. #32 AWG Magnetic copper wire.
approximately 190 turns per slot, it was settled to 500 turns
per slot. Therefore, the conclusive parameters of the generator
are listed in Table I.
 4

Fig. 2. PVC Pipe. Fig. 7. Pair of scissors.

Fig. 3. Herbalife powdered drink bottle. Fig. 8. L-square ruler.

Fig. 4. Sandpaper. Fig. 9. Wood handsaw.

Fig. 5. Screwdriver set. Fig. 10. Metal handsaw.

Fig. 6. Hammer. Fig. 11. Flathead screwdriver.

 5

Fig. 12. Philips’s screwdriver.

Fig. 17. Digital Multimeter.

Fig. 13. Soldering iron.

Fig. 18. Drawing compass.

Fig. 14. Drill.

Fig. 19. Carpenter's tape.

Fig. 15. Drill bit.

Fig. 20. Neodymium magnets (N52 NdFeB).

Fig. 16. Multimeter.

Fig. 21. Butane Gas.

 6

Fig. 22. Marking tools. Fig. 27. Arduino-based turn counter for copper winding.

Fig. 23. Wrenches. Fig. 28. Glue.

APPENDIX B
Procedures

Fig. 24. Combination pliers.

Fig. 29. First meeting and conceptualization of the generator (April 4).

Fig. 25. Measuring tools.

Fig. 26. All-purposes oil

 7

Fig. 30. Design of the Archimedes’ screw (April 6).

Fig. 31. Salvaged rotor (April 22).

Fig. 35. Purchasing of the magnetic copper wire (May 4).

Fig. 32. Creation of helical screw blade (April 24).

Fig. 33. The initial Archimedean screw (April 25).

Fig. 36. Fabrication of the wooden frame for Archimedes’ screw (May 5).

Fig. 37. Initial product of the Archimedean screw (May 6).

Fig. 34. Final plastic clearance for the Archimedes’ screw (May 1).
 8

Fig. 41. First design of the armature (May 13).

Fig. 38. First test conducted to measure the angular velocity (May 8).

Fig. 39. The final product of the Archimedean screw generator (May 10).

Fig. 42. Rearrangement of rock formation in the river beside SorSU Baribag.

Fig. 43. Final test conducted to measure the angular velocity (May 15).

Fig. 40. Second test conducted to measure the angular velocity (May 12).
 9

IV. ACKNOWLEDGMENT
The group are using this opportunity to express their deep-
est gratitude to everyone who supported them throughout this
project. They are indebted to those people who helped them
directly and indirectly in preparing this project. The project
will not come to life and could not have been possible without
the assistance and guidance of so many people.
The group would like to give their sincerest gratefulness to
their project and Electrical Machines 2 (EM 2) adviser and in-
structor, Engr. Robert Christian Labalan, for providing super-
Fig. 44. Magnetic wire rewinding (May 15). vision and support during the whole project period. They
would also like to thank him for the patience and knowledge
he shared. It was a privilege and honor to work and study un-
der his guidance.
Lastly, to our parents for their consideration, patience, and
undying support throughout the making of the project. As well
as their words of encouragement for all those nights that we
have spent making the research project.

V. REFERENCES
[1] I. Boldea. Electric Generators and Motors: an overview.
Ces Transactions On Electrical Machines And Systems. [On-
Fig. 45. Rewinding of the magnetic coil (May 23).
line]. 1(1). Pp. 3-14. Available: doi: 10.23919/
TEMS.2017.7911104

[2] K. Thomas, et. Al. A Permanent Magnet Generator for En-

ergy Conversion from Marine Currents: No Load and Load
Experiments. ISRN Renewable Energy. [Online]. pp. 1-7.
Available: doi: 10.5402/2012/489379

[3] F. G. Destreza. (2014, Mar.). Portable Self-Sustaining

Electric Generator. ISSN 2222-2863. [Online]. 5(1), pp. 38-
44. Available:
https://www.researchgate.net/publication/309462898_Portable
Fig. 46. Final design of the armature (June 4).
_Self-Sustaining_Electric_Generator

[4] G. Muller and J. Senior. (2010, Apr.). Simplified theory of

Archimedean screws. Journal of Hydraulics Research. [On-
line]. 47(5), pp. 666-669. Available: doi:10.3826/
jhr.2009.3475

[5] A. Dragomirescu, “Design considerations for an Archime-

dean screw hydro turbine,” in IOP Conf. Ser.: Earth Environ.
Sci. 664, 2021

[6] K. J. Songin, “Experimental Analysis of Archimedes

Screw Turbines,” M.S. thesis, Master of App. Sci. in Eng.,
Univ. of Guelph, Ontario, Canada, 2017.

[7] M. I. Maulana, et. Al., “Blade number impact on pressure

and performance of Archimedes screw turbine using CFD,” in
AIP Conf. Proc. 1931, 2018, pp. 1-7.

[8] Utah State Today. (2018, Sept.) A New Twist on

Fig. 47. Final design of the AC generator. Archimedes’ Screw. Utah State University. Old Main Hill, Lo-
gan, UT. [Online]. Available:
https://www.usu.edu/today/story/a-new-twist-on-archimedes-
screw#:~:text=Turbine%20efficiency%3A%2090%20percent
%20(average)
 10

News Editor of Bulusan Aguingay of Bulusan National High School last

2019-2020.
[9] Adams Magnetic Products. (n.d.). “Gauss and Pull Calcu-
lators for Magnets,” https://www.adamsmagnetic.com/gauss- Joshua G. Halum was born in Bulusan, Sorsogon
and-pull-calculators-for-magnets/?calculator=rectangle (ac- on June 2, 2002. He completed his senior high
cessed June 5, 2023). school with honors last 2020 at Bulusan National
High School. He is taking a BSEE at SorSU.
He completed the 8-hour OSH with 2-hour train-
ing for BOSH for Safety Officer 1 last April 25,
VI. BIOGRAPHIES 2023, conducted by the DOLE. He is the former
president of the science club of Bulusan National
Leemuel D. Castuera was born in Sorsogon, Sorso-
High School last 2019-2020.
gon, on the 19th of May 1997. He studied Electron-
Mr. Halum is a member of SorSU-IIEE since
ics and Communications Engineering (ECE) with a
2020.
specialization in Industrial Automation and Process
Control at Mapua Institute of Technology, currently
known as Mapua University. Due to the COVID out-
break, he decided to transfer school and take BS
Electrical Engineering (BSEE) in Sorsogon State
University (SorSU).
His transfer to SorSU has the sole intention of
finishing his ECE degree. Upon passing the entrance exam, in SorSU, he de -
cided to claim his honorable dismissal to his previous school and learned that
being part of SorSU’s 1st batch of ECE, he has to wait for 4 years before he
can claim his graduation march. Luckily, he was offered a 2-year degree in
Electrical Engineering upon recalibration of his transcript of records. He plans
on finishing both degrees and claiming both Professional Regulation Commis-
sion (PRC) licenses.
Mr. Castuera completed the 8-hour Occupational Safety and Health Ori-
entation (OSH) with 2-hour training for Basic Occupational Safety and Health
(BOSH) for Safety Officer 1 last April 25, 2023, conducted by the Department
of Labor and Employment (DOLE).

Clare Dianne F. de Ocampo was born in Sor-

sogon City, Sorsogon on January 1, 2002. She
graduated senior year of high school with hon-
ors in 2020 at SorSU, formerly Sorsogon State
College (SSC), where she is currently pursuing
a Bachelor of Science in Electrical Engineer-
ing (BSEE).
She completed the 8-hour OSH with 2-hour
training for BOSH for Safety Officer 1 last April
25, 2023, conducted by the DOLE.
Ms. de Ocampo has been a member of the Insti-
tute of Integrated Electrical Engineering (IIEE) since
2020. She also serves as the Graphics Editor of Gen-
eratrix, an official publication of the College of En-
gineering and Architecture at SorSU, since 2022.

Isaiah Paul G. Estuye was born in Gubat, Sorso-

gon on November 18, 2001. His interest in electric-
ity from an early age made him pursue BSEE at
SorSU, formerly known as SSC, where he, as well
as, completed his high school years.
He completed the 8-hour OSH with 2-hour training for BOSH for
Safety Officer 1 last April 25, 2023, conducted by the DOLE.
Mr. Estuye membership as a student of the SorSU includes the IIEE since
2020 and the SorSU Marching Band’s saxophonist since 2022. He was also
one of the SorSU Marching Band’s drummers last 2014-2020.

Pauline G. Fresto was born in Bulusan, Sorsogon

on June 30, 2002. She graduated senior high school
with honors at Bulusan National High School last
2020, and is currently a third-year college student
taking BSEE at SorSU.
She completed the 8-hour OSH with 2-hour
training for BOSH for Safety Officer 1 last April
25, 2023, conducted by DOLE. She was one of
the representatives of her school in the 2nd Divi-
sion Science Olympics, conducted last 2018.
Ms. Fresto is a member of IIEE – SorSU Chapter and a scholar of the De-
partment of Science and Technology (DOST) since 2020. She is also the on-
going Associate Editor of the official publication of the College of Engineer-
ing and Architecture, Generatrix, at SorSU. She was the former Associate and