March 24 2008
By DanB, Section Homebrewed Electricity Posted on Mon Mar 24th, 2008 at 07:58:56 PM MST
bearing failure, knife switches & other fun stuff

Sorry for the blurry picture.  This is a 10' machine that's been flying on a really good site now for 2 years.  It's the first bearing failure I've seen.  This wind turbine has 2" dia round magnets in it, 48V and the coils are 105 turns of #15 gage wire. The owners claim that they often see a steady kW 24/7 for the most part.  On cloudy weeks when they get no solar, this runs their whole house.  I'm not sure of their energy consumption but it's a fairly 'normal' house with electric fridge, dish washer, cloths washer/dryer and in floor radiant heat (which means pumps are running).  At any rate, the bearing only lasted two years.  Could be we didn't grease it well enough, could be that its a low quality (or too small) bearing.  Easy fix anyhow.. at least for two more years! This is the vinyl ester stator from the same machine.  It shows definite signs of getting hot... but I think it's OK (maybe it won't get worse!) Rich putting the same machine back together with new bearings.  We've also been busy since Nicaragua building new machines. Daphne wanted to come up and learn to build wind turbines.  She made a stator last thursday. This was my souvenier from Nicaragua.. a bunch of nice big knife switches form the hardware store.  You just can't find stuff like this around here. Another shot of the 30 amp knife switch (double pole double throw) and the single throw 60 amp switch.  We'll be offering these soon on our shopping cart, I think they're cool.  If you take the cover off they're just like any other 'antique' porcelain knife switch.  I have a bunch more of these coming. This is another new product we'll be adding to the shopping cart within the week, the 'Doc Wattson' meter.  It's probably the best bang for the buck if you want to keep track of Voltage, Current, kWh, Wh, Peak Current, and low voltage.  Lots of data for $59.95 and they're good up to 100 amps (I've pushed mine over 130) Our neighbor John came up today with his new bike.  He made it for $40 out of two wrecked hondas (different types), a harley seat.  The fuel tank and front wheel are of unknown origin.  The handle bars are from a small mini-bike. He didnt have a muffler though... I offered him the one shown. 'loud pipes save lives'...??

March 24 2008 | 20 comments (20 topical, 0 editorial)

Re: March 24 2008 (3.00 / 0) (#1) by DamonHD (d@hd.org) on Mon Mar 24th, 2008 at 02:25:39 PM MST (User Info) http://www.earth.org.uk/

Forgive me DanB as an acoustics and road-law newbie, IANAL etc, but my guess is that that silencer would not be acceptable to local police.  B^> (The local teenagers would kill for it though!) I use an E-Flite meter which I think may be similar to the 'Doc Wattson', though I use mine mainly as a self-powered digital voltmeter and don't leave it connected to the battery all the time.  It might be worth looking out for as an alternative stock line... Rgds Damon

Re: March 24 2008 (3.00 / 0) (#2) by DanB (danb@*no spam*otherpower.com) on Mon Mar 24th, 2008 at 02:35:49 PM MST (User Info) http://www.otherpower.com/

Hi Damon - I had never seen or heard of that meter till you mentioned it.  It looks very nice/useful as well.. very similar.  To make life easy for other folks: http://www.e-fliterc.com/Products/Default.aspx?ProdID=EFLA110 [ Parent ]

Re: March 24 2008 (3.00 / 0) (#3) by DanB (danb@*no spam*otherpower.com) on Mon Mar 24th, 2008 at 02:38:57 PM MST (User Info) http://www.otherpower.com/

One drawback of the eflight meter is the upper limit of 50V. [ Parent ]

Re: March 24 2008 (3.00 / 0) (#5) by DamonHD (d@hd.org) on Mon Mar 24th, 2008 at 03:35:04 PM MST (User Info) http://www.earth.org.uk/

The 50V limit is no limit for me on my tiny 12V system!  B^> Rgds Damon [ Parent ]

Re: March 24 2008 (3.00 / 0) (#17) by ghurd on Tue Mar 25th, 2008 at 01:38:25 PM MST (User Info)

"that silencer would not be acceptable to local police" meaning then they might notice the lack of lights, License Plate, and Registration? I'm sure he wouldn't use it on public roads either way. "It was a '49, '50. '51, '52..."  J. Cash G- [ Parent ]

Re: March 24 2008 (3.00 / 0) (#18) by DamonHD (d@hd.org) on Tue Mar 25th, 2008 at 03:23:20 PM MST (User Info) http://www.earth.org.uk/

What, you need that stuff in the US?  B^> The only way for a boy racer on a motorbike to get arrested in the UK it seems is to actually film themselves for YouTube doing at least about twice the maximum UK speed limit, preferably though a housing estate past a nursery school etc etc, and post the clip with full details of where they can be found, girls they wished they had known, etc... Rgds Damon [ Parent ]

Re: March 24 2008 (3.00 / 0) (#4) by TomW on Mon Mar 24th, 2008 at 03:34:10 PM MST (User Info)

Ok, Dan; I am down on the list for [unspecified #] knife switches and at least one of the Doc Wattsons. Been looking for both for spring installation. Those bull horn bars on the scooter must be fun off road? Love the resonator on the bike, too. TomW "Education consists mainly of what we have unlearned."--Mark Twain

Re: March 24 2008 (3.00 / 0) (#6) by Sly on Mon Mar 24th, 2008 at 04:24:02 PM MST (User Info)

Hi Dan, Bearing failure: A friend of mine when I told him I was not going to put a seal in suggested that I pop the spring in the seal and install it. He says that there would be no or very little mechanical friction/resistance but this would still offer about 50% protection against rain and snow. But then again as you indicated first bearing failure you've seen just a thought. Will keep my eyes open for the "Doc Wattson" as I will need something like this eventually!! P.S. The bike reminds me a bit of the Easy Rider movie!!! sly

Re: March 24 2008 (3.00 / 0) (#7) by jmk on Mon Mar 24th, 2008 at 05:35:23 PM MST (User Info)

Well, if he is rideing everyone will know where he is at. At the least you know when he is coming and leaving.   jmk

Re: March 24 2008 (3.00 / 0) (#8) by JW on Mon Mar 24th, 2008 at 06:20:07 PM MST (User Info)

DanB,  Did the hub feature a 'rear-seal', from here, it looks like the weather may have washed it out. I know the spring loaded hub seals can make it tough to R&R hub assys and make it difficult to re-pack the rear bearing. I always use great care when I encountor one on a hub. Most of the time its gotta be replaced, because they can be rough to remove(when there rusty, etc).  As for that phono-graph loudspeaker, on the motorcycle, it must have been around in the time of Thomas Edison. Looks pretty sturdy, I dont see a braket. Although, one of those Conquistador helmets would go perfectly with that.  :) JW [ Parent ]

Re: March 24 2008 (3.00 / 0) (#9) by blueyonder (windwoodgood at yahoo dot co dot uk) on Mon Mar 24th, 2008 at 08:19:39 PM MST (User Info)

now if you could just have got one of the dogs to sit and look inside the horn.   you could have said HIS MASTERS VOICE.      so if it was a honda.  you might need a pekinese . its a ill wind that dos no good

Re: March 24 2008 (3.00 / 0) (#10) by JW on Mon Mar 24th, 2008 at 08:30:44 PM MST (User Info)

"now if you could just have got one of the dogs to sit and look inside the horn." Was'nt that the (TM) for RCA.. Back in the 60's. JW [ Parent ]

Re: March 24 2008 (3.00 / 0) (#11) by TomW on Mon Mar 24th, 2008 at 08:33:02 PM MST (User Info)

"His Masters Voice" Yep. Old time RCA Logo. TomW "Education consists mainly of what we have unlearned."--Mark Twain [ Parent ]

Re: March 24 2008 (3.00 / 0) (#12) by terry5732 on Mon Mar 24th, 2008 at 09:39:11 PM MST (User Info)

Some of those horns fetch big bucks around here.

Re: March 24 2008 (3.00 / 0) (#13) by ruddycrazy on Tue Mar 25th, 2008 at 12:43:17 AM MST (User Info)

Hi Dan,        With tapered bearings they are designed to have about a 0.002" preload depending on size. When I set tapered bearings at work I generally go or around 0.001-0.002" end float so when the gearbox gets up to temp the expansion will give the required preload.        As a wind genny only does low speeds (200-300 rpm) I dont think the bearing would heat up too much so personally I'd go for a zero end float/preload. Also with grease make sure they are fully packed with grease and the seals on each end have some crush on the seal journal. Petroluem jelly on the seal face and in the seal cavity ensures the seal will be lubricated long term and it does help in wear prevention on the sealing journal.        Here's thought on bearings for the larger type turbines. Have 2 tapered bearings back to back set with about a 0.001" end float then about 5-6" down the shaft put a spherical bearing. This arrangement is widely used in gearbox's and would lend itself to RE on larger machines. Please note these are just my thoughts and I'm not trying to tell you how to mount bearings as I know you guys have been doing it for years. Cheers Bryan1

Re: March 24 2008 (3.00 / 0) (#14) by Boss (brians.outfit(at)gmail.com) on Tue Mar 25th, 2008 at 07:00:58 AM MST (User Info) http://www.outfitnm.com

No doubt the doggies ran for cover if and when you fired that bike with the resonator attached! Nice to see the new/old-timey products going online. The owners of the bearing failed 10 footer were seeing 1000 watts steady? That's encouraging.   Brian Rodgers

Re: March 24 2008 (3.00 / 0) (#15) by Bruce S (bruce(dot)stahl <at>gmail (dot)(com)) on Tue Mar 25th, 2008 at 08:26:54 AM MST (User Info)

DanB; Those Watts Up "rc" meters should have an power input on the source side, you can fit a sourced voltage (3vdc I think) in there to keep the meter working even when the source is not connected.:-) Nice units too, I have one that tops out at 60Vs. I use it for in/out put of the little HF panels, as well as one in the trike as a battery charge indicator and charger. It doesn't care what type of battery chemistry you have. I "LIKE" the muffler, the saying around here is that a noisy bike is a safe bike! Cheers Bruce S

Re: March 24 2008 (3.00 / 0) (#16) by psycho D on Tue Mar 25th, 2008 at 12:29:33 PM MST (User Info)

hey dan,   i got those exact same knife switches in costa rica. must be a latin american company supplying all the local countries. my brother used them in his system and i think i have one or two left. i'll have to come up and compare them.              see you soon,                    android

Re: March 24 2008 (3.00 / 0) (#19) by tecker on Tue Mar 25th, 2008 at 06:03:42 PM MST (User Info)

Insulate the stator connections before it goes back out . Polyurethane caulk . That stuff stick to anything if it's clean . Could be loading up between Two phases with rainy weather. Just had to butt in there .

Re: March 24 2008 (3.00 / 0) (#20) by Sly on Wed Mar 26th, 2008 at 06:52:41 PM MST (User Info)

DanB, Have you changed your method of assembling the hubs without the rear seal? I was under the impression you were not installing them and this is why I brought up the recommendation made to me i.e. removing the spring in the seal to reduce mechanical friction. Just curious what is your latest method since I am slowly approaching this stage of assembly. Tks Sly

Login

Make a new account Username: Password:

Total Views

234 Scoop users have viewed this posting.

Related Links

· magnet · Also by DanB