Searl-Effect Generator: Design & Manufacturing Procedure
by S. Gunnar Sandberg
(School of Engineering & Applied Sciences, University of Sussex)
June 1985
The objective of this report is to reconstruct the experimental work carried out between 1946 and 1956 by John R. R. Searl that concerns the geometry, materials used, and the manufacturing process of the Sear1-Effect Generator (SEG).
The information given here is based on private communication between the author and Searl and should be considered preliminary as further research and development may give reason to alter and/or update the content.
The Gyro-Cell
The SEG consists of a basic drive unit called the Gyro-Cell (GC) and, depending on the application, is either fitted with coils for generation of electricity or with a shaft for transfer of mechanical power. The GC can also be used as a high voltage source. Another and important quality of the GC 1s its ability to levitate.
The GC can be considered as an electric motor entirely consisting of permanent magnets in the shape of cylindrical bars and annular rings.
Figure 1 shows the basic GC in its simplest form, consisting of one stationary annular ring-shaped magnet, called the plate, and a number of moving cylinder-shaped rods called runners.
Figure 1
During operation each runner is spinning about its axis and is simultaneously orbiting the plate in such a manner that a fixed point p on the curved runner surface traces out a whole number of cycloids during one revolution round the plate, as shown by the dotted lines in Figure 2.
Figure 2
The Magnetic Field Configuration
Magnetic Materials
Manufacturing Procedure
Stage 1: Magnetic Materials & Bonding Agents
It is feasible that future research will reveal other magnetic raw materials to be cheaper and/or more efficient than the ones used in the original experiments. It is also possible that other types of binder may improve the performance.
Stage 2: Weighing
In general, to produce efficient magnets the right amount of each element contained in the ferromagnetic powder is crucial. It is therefore reasonable to suggest that when mixing different types of powders an optimal weight ratio does exist that will produce a 'best' magnet.
At present, however, this weight ratio is not known for the powders used by Searl in his past experiments. Together with new magnetic materials and optimization of generator geometry, this is an area in which research efforts could be profitable.
In general, the amount of binder used should be as small as possible to achieve maximum mass density of bonded magnets. However, the possibility that the binder is taking an active part in the generation of the Searl-Effect must not be excluded. For instance, the dielectric properties of the binder may play an active role in the electromagnetic interactions taking place in the SEG. If that is the case, then a further amount of bonding material may be beneficial.
Stage 3: Mixing
The mixing is an important process which will decide the homogenity and reliability of the finished product. A homogeneous mixture can be achieved by using turbulent air flow inside the mixing container The experiments did show that an improved performance was achieved if all magnets for the same generator were made from the same batch.
Stage 4: Moulding
During the moulding process the compound- consisting of ferromagnetic powders. and thermoplastic binder is compressed and simultaneously cured by heating. Figure 8 illustrates the tool used for making 'blinds'. A 'blind' is an unmagnetized runner or plate/part of plate. When manufacturing large plates (Dp > 30 cm) it may be necessary to make them in segments rather than in one piece.
Figure 8
The figures given below should be considered as guidelines only, since correct data are not available regarding the influence of the moulding process on the Searl-Effect.
1. Pressure: 200-400 bars
2. Temperature: 150 C-200 C
3. Compression time: > 20 minutes.
Before releasing the pressure the mould must be allowed to cool.
Stage 5: Machining
This process can be bypassed if the weighing and moulding procedures are carried out correctly. However, it may be necessary to polish the cylindrical surface of runners and plates.
Stage 6: Inspection
Control of dimensions and surface finish.
Stage 7: Magnetization
Runners and plates are individually magnetized in a combined DC and AC-field during one on-off duty cycle. Figure 9 illustrates the magnetizing circuit.
Figure 9
The function of the automatic control switch (ACS) is to simultaneously switch on the DC-current, idc and the AC current, iac at such a time, t = ton, that the instantaneous value of the total magnetomotive force (MMF) is always positive. Thus:
MMF = idcN1 + iacN2 > 0
Where N1 is the number of turns in the DC-winding and N2 is the number of turns in the AC winding.
Figure 10 shows the total MMF as a function of time.
Figure 10
Stage 8: Inspection
Stage 9: Assembling
Searl-Effect Generator Full
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