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Author Topic: Homemade Generator Update  (Read 5581 times)

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RedLance

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Homemade Generator Update
« on: November 25, 2009, 09:55:48 AM »
I've been working on this for awhile now.  Got a new job back in Feburary that includes access to a nice fabrication shop.  I made the base plate out of 10ga steel bent in a U.  Used our giant nibbler ( A PullMax) to make the "face" holes for the engine and alternator.  I used a serpintene belt with a tensioner, instead of the V belt with a slot adjustment.  The engine pulley is from a GM power steering pump.  I bored it out, then welded on a couple set collars and made a keyway in the whole thing.  The control panel has a 0-50 volt meter 0-100 amp meter, switch and fuse for the alternator, and a kill switch and starter button for the engine.  I broke down and bought a brand new surplus 6.75hp engine with electric start.  The Craftsman I was going to use conked out, and was only 3.5hp anyway.  The shunt for the amp meter is mounted to the base plate with home made insulated stand offs.  I made the HomePower controler circuit, and mounted it on the back of the control panel.  I have several extra circuit boards for this if anyone is interested.  Set up a set of 4ga jumper cables with Anderson connectors to easily plug it into the batteries.  I plan to use it to equalize charge my pallet jack batteries, as well as power my 2000 watt inverter along with the batteries.


Here's the pictures.  The white splotches are an attempt to block out my messy shop. :)










« Last Edit: November 25, 2009, 09:55:48 AM by (unknown) »
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97fishmt

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Re: Homemade Generator Update
« Reply #1 on: November 25, 2009, 10:24:30 AM »
Hi, Does the alternator run cool enough when putting out high amps?
« Last Edit: November 25, 2009, 10:24:30 AM by 97fishmt »
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RedLance

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Re: Homemade Generator Update
« Reply #2 on: November 25, 2009, 12:18:03 PM »
Well, I haven't actually gotten to run it yet.  I still have to finish the wiring.  This alternator has it's own internal fan, so it should be fine.  It's supposed to be a 130 amp unit.  I'll sure keep an eye on it and let you know though.
« Last Edit: November 25, 2009, 12:18:03 PM by RedLance »
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Ungrounded Lightning Rod

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Re: Homemade Generator Update
« Reply #3 on: November 25, 2009, 02:12:21 PM »
Where's the alternator's fan?
« Last Edit: November 25, 2009, 02:12:21 PM by Ungrounded Lightning Rod »
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RedLance

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Re: Homemade Generator Update
« Reply #4 on: November 25, 2009, 07:43:01 PM »
It's inside the case, just behind the pulley.  Trust me, it's there, I put new bearings in the alternator, and saw it myself. :)
« Last Edit: November 25, 2009, 07:43:01 PM by RedLance »
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jaskiainen

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Re: Homemade Generator Update
« Reply #5 on: November 26, 2009, 07:06:50 AM »
Hi!


How about the direction of the fan should rotate?

Does it matter in your case?


I'm about to built one or two of those generators in this winter and

most of the generators i've seen must be upside down to get the cooling

efficiency enough. That or different type of fan.

Just a thought.

« Last Edit: November 26, 2009, 07:06:50 AM by jaskiainen »
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Junkie

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Re: Homemade Generator Update
« Reply #6 on: November 26, 2009, 11:48:55 AM »
Wow, nice job. It looks better than most commercially available generators!
« Last Edit: November 26, 2009, 11:48:55 AM by Junkie »
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RedLance

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Re: Homemade Generator Update
« Reply #7 on: November 26, 2009, 08:02:49 PM »
Well, I checked on this today, and it seems that the 3G alternator that I used is supposed to run Clockwise (facing the pulley, I assume) but in my setup runs counter clockwise.  According to the Epicenter website, this shouldn't matter.  I suppose I'll have to put a temperature probe on it...


Thanks for the comments!

« Last Edit: November 26, 2009, 08:02:49 PM by RedLance »
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RedLance

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Re: Homemade Generator Update
« Reply #8 on: November 26, 2009, 08:04:43 PM »
Well...I don't know about all that, but thanks!
« Last Edit: November 26, 2009, 08:04:43 PM by RedLance »
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gizmo

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Re: Homemade Generator Update
« Reply #9 on: November 27, 2009, 10:01:54 PM »
I've built a portable petrol motor driven charger like this, and I too was worried about the fan direction and cooling. So I took the fan off, flattened it out and bent the fins the other way. Its not that hard to do. http://www.thebackshed.com/Windmill/articles/PortableCharger.asp


Its a handy thing to have, especially when trying to start a car with a flat battery.


Glenn

« Last Edit: November 27, 2009, 10:01:54 PM by gizmo »
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fabricator

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Re: Homemade Generator Update
« Reply #10 on: November 28, 2009, 05:23:04 PM »
Turn your alternator over and mount it from the bottom of the plate, rotation reversed.
« Last Edit: November 28, 2009, 05:23:04 PM by fabricator »
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RedLance

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Re: Homemade Generator Update
« Reply #11 on: November 29, 2009, 09:30:43 PM »
My fan is welded to the front of the rotor...Not sure how easy it will be to reangle the fins, but I'll take a look.  Thanks!
« Last Edit: November 29, 2009, 09:30:43 PM by RedLance »
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RedLance

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Re: Homemade Generator Update
« Reply #12 on: November 29, 2009, 09:32:13 PM »
Yeah, I could do that...but then I'd have to space the whole unit up off the ground, to clear the alternator, which I could also do.  I might be able to reverse the rotation by re routing the belt too...I'll have to see.
« Last Edit: November 29, 2009, 09:32:13 PM by RedLance »
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Ungrounded Lightning Rod

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Re: Homemade Generator Update
« Reply #13 on: November 30, 2009, 01:10:55 PM »
Good.


Now if you're spinning the alternator the right way you're in like Flynn.


(Spin it the wrong way and it will still generate but won't cool as well.)


The reason I mention that is that I hear a lot of lawnmotor engines and car alternators spin such that the alternator rotates the "wrong" way if you mount them on a plate, shafts down, with pulleys and a belt underneath.

« Last Edit: November 30, 2009, 01:10:55 PM by Ungrounded Lightning Rod »
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Norm

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Re: Homemade Generator Update
« Reply #14 on: November 30, 2009, 06:52:16 PM »
Build an enclosure around the alternator and

over to the blower shroud of the engine so about

half of the air to the engine is sucked thru

the alternator....should work ?
« Last Edit: November 30, 2009, 06:52:16 PM by Norm »
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