Author Topic: Generator Experiment  (Read 1846 times)

Offline kuhncw

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Re: Generator Experiment
« Reply #15 on: January 21, 2022, 01:34:08 AM »
Very interesting Maury. 

How did you wind the coils?

Chuck

Offline maury

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Re: Generator Experiment
« Reply #16 on: January 21, 2022, 02:27:23 PM »
Chuck, good question. Thanks for tuning in.
I made a coil winder setup for my lathe. First I 3D printed a spool that would just
fit into the stator pockets. I designed the geometry so it would give me 300
turns of #28 wire and have the coil just fit snug in the stator. I had no idea how
much output I'd get, just a starting point.
I ordered a counter from a surplus vendor, and went about designing the cam and
trip for the counter. I also printed a bracket to mount the counter in my quick
change tool post.
Then it was simply a matter of winding the wire until the spool was full.
"The trouble with socialism is that you eventually run out of other people's money."... Margaret Thatcher

Offline kuhncw

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Re: Generator Experiment
« Reply #17 on: January 21, 2022, 04:20:07 PM »
Maury,

Thanks.   You just ran low rpm and fed the wire by hand.

Simple and it works.

Chuck

Offline ddmckee54

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Re: Generator Experiment
« Reply #18 on: January 21, 2022, 06:34:19 PM »
How easy was it to get the coil off the 3D printed form?

Offline bent

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Re: Generator Experiment
« Reply #19 on: January 21, 2022, 07:02:48 PM »
Following along with interest also. :popcorn: :ThumbsUp:

Offline maury

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Re: Generator Experiment
« Reply #20 on: January 26, 2022, 05:09:46 PM »
Ok Folks, so here's the scoop. As I mentioned previously, I wired the stator as a 3
Phase generator. I used a 6 diode fill wave bridge to rectify the AC. The output was
disappointing at about 2 1/2 VDC. I could have made a mistake in wiring the stator
but I believe i did it correctly.
There were other inconveniences with the coils. I was able to get them where they
belonged, but it was a hassle and I had to use a lot of glue. So I went back to
Solidworks and made the stator a bit wider to accommodate spools. I designed a
spool to be printed, with with holes, and I redesigned the winder to hold the
spools.
( By the way, to answer a previous question, yes, the coil came off the winder
ok, I added 2 deg of draft to the winder, enabling the coil to be removed. It still
wasted to come apart until I was able to apply the tape.)

So I built the new stator and wired the coils in series. WOW! what an improvement.
Testing the generator at about 300 to about 800 RPM the output ranged from
5 VDC to 10 VDC. with a 150 ohm load.

"The trouble with socialism is that you eventually run out of other people's money."... Margaret Thatcher

Offline Roger B

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Re: Generator Experiment
« Reply #21 on: January 27, 2022, 08:27:59 PM »
As I think Per asked earlier, do you have iron cores in the coils? It is not clear from the pictures.
Best regards

Roger

Offline maury

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Re: Generator Experiment
« Reply #22 on: January 27, 2022, 09:12:57 PM »
Roger, sorry, guess I missed the question.
No, there are no iron cores in the coils. I suspect that would enhance the output, but the original
information I had from the videos I watched had no cores.
For my purposes, the generator has enough output as is, and I believe it may have enough so I could scale it down a bit. Currently, it's just under 5" in Dia.

At this point I'm going to call the project done, and am working on a steam engine to drive it, and a street lamp accessory. I'd like to thank everyone for their comments and questions, and for tuning on. If anyone wants design
info about this project, just let me know. I'd post the design, but there doesn't seem to be a way to do it on this
site.

maury
"The trouble with socialism is that you eventually run out of other people's money."... Margaret Thatcher

Offline maury

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Re: Generator Experiment
« Reply #23 on: January 27, 2022, 09:31:31 PM »
I can go ahead and share a peek at the engine design I'm working on. It uses some of the features of engines I've worked on
previously: the Dickson steam engine, and the Gothic Beam engine.
The design is not complete at this point. I will be printing 3D patterns to make the castings. Looks like it will be made in
bronze, and I'll be making the bar stock parts from 303 Stainless. For reference o0n size, the flywheels are currently 5" dia.
maury
"The trouble with socialism is that you eventually run out of other people's money."... Margaret Thatcher