Author Topic: axial generator with lamination core (Read 114374 times)

MagnetJuice · « **Reply #165 on:** February 18, 2019, 02:43:11 PM »

Ok, carry on. I have other projects that require my attention too.

If you have questions, just ask.

Ed

mbouwer · « **Reply #166 on:** February 19, 2019, 10:42:11 AM »

Hollow blade axle mounting rings outside diam. 92 mm

Adriaan Kragten · « **Reply #167 on:** February 20, 2019, 12:08:44 PM »

It's true that you can better use a real resistor than a lamp bulb as load. The disadvantage of a lamp bulb is that the resistance is very low if it is cold so then it works almost like a short-circuit and you can get a very high peak current.

mbouwer · « **Reply #168 on:** February 21, 2019, 04:08:48 AM »

So no light bulbs as load.
The basic blade suspension ring (820 grams) loosened from the mold.
I think in the next test set up this ring can be integrated in the front magnetring.

Bruce S · « **Reply #169 on:** February 21, 2019, 08:52:45 AM »

What metal did you mold/make that with?

mbouwer · « **Reply #170 on:** February 22, 2019, 04:40:55 AM »

Small pieces of 2 mm sheet steel of ordinary steel.
To reduce weight I remove material, on less stressed places, by means of grinding.

mbouwer · « **Reply #171 on:** February 23, 2019, 05:19:32 AM »

Completed basic blade suspension ring (1708 grams)
Now I can go on with the blade hubs.

midwoud1 · « **Reply #172 on:** February 23, 2019, 05:52:51 AM »

Piece of craft.

FBM

mbouwer · « **Reply #173 on:** February 24, 2019, 06:13:46 AM »

It is a base. There'll be additions for the blade adjustment and fastening the spinner.

Now I'm working on the polyester slide bearings which fit Reply#164
They get a wear layer of copper filings.

Frank S · « **Reply #174 on:** February 24, 2019, 08:47:38 PM »

Looking at the blade suspension ring I can't help but feel your machine is going to have a lot of stress in that area Not trying to be an arm chair engineer but it looks like it is going to require another 6 sided piece of metal welded to the blade hub mounts to tie the outer edges together

mbouwer · « **Reply #175 on:** February 25, 2019, 04:34:49 AM »

You mean like this.

Frank S · « **Reply #176 on:** February 25, 2019, 10:58:37 AM »

Yeah, something to help distribute the stress . The force on the blades will be tremendous which will try to bend the mounting plus as the blades pass the tower the forces are deflected causing that blade to try and relax a little or be deflected angular to the mounting. metal fatigue quickly sets in. Part of the reason air plane props have much stronger mountings than looks necessary. The forces are the same just opposite of how a turbine receives them transmitted from the tips inward as opposed to the hub driving them

Frank S · « **Reply #177 on:** February 25, 2019, 11:06:27 AM »

One way to test your mounting piece would be to lock it down to a fixed table mount a single blade then pull on the tip forward backward and up and down simulating the wind force that will be exerted. Check with a dial indicator touching the blade hub at its mounting

mbouwer · « **Reply #178 on:** February 27, 2019, 05:14:00 AM »

Nice way to test the blade and the blade bearings. And to see if the blade pitching keeps on working in rough conditions.

The slide bearing and a threaded sleeve anchor is to be incorporated in the polyester blade hub.

mbouwer · « **Reply #179 on:** March 03, 2019, 06:53:23 AM »

Blade suspension ring assembly with the blade roots and the operating levers.

mbouwer · « **Reply #180 on:** March 04, 2019, 05:38:07 AM »

Pitch bearing. Now I want to make three small clevises.

DamonHD · « **Reply #181 on:** March 04, 2019, 08:19:24 AM »

Goodness, how I envy your fabrication skills!

Rgds

Damon

SparWeb · « **Reply #182 on:** March 04, 2019, 10:21:58 PM »

I must say I do too.
These last photos of the assembly reveal a lot of the machinery that (until now) has not been clear to its purpose or function.
Thank you!

mbouwer · « **Reply #183 on:** March 05, 2019, 08:40:35 AM »

Allow me to underline it is just a test set up.
I'm trying to improve the components and (critical) forum comments contribute to this.

SparWeb · « **Reply #184 on:** March 05, 2019, 10:48:45 PM »

Thank you. We enjoy seeing the progress, even as tests. Especially, so, in fact.
I am looking forward to seeing the rigging of the pitch arms, too.

mbouwer · « **Reply #185 on:** March 06, 2019, 05:59:21 AM »

As part of the reinforcement rods from Reply # 175 I have welded mounting plates on to the blade axle mounting rings.

JW · « **Reply #186 on:** March 06, 2019, 07:00:10 PM »

Hey Mbouwer

Im wondering if you have made any 3D CAD models of your work.

Was in conversation with some other fellows on steamautomoble.com about a CAD software. I could give you a link.

https://steamautomobile.com:8443/ForuM/read.php?1,28227,28360#msg-28360

mbouwer · « **Reply #187 on:** March 07, 2019, 06:04:29 AM »

Until now I do'nt have them but perhaps I can form part of a team with multiple disciplines.
It would be nice if a CAD draughtsman could be part of the team.

Blade pitch components.

mbouwer · « **Reply #188 on:** March 08, 2019, 07:39:40 AM »

Feathered position. The steering rod protruding.
If I could make a main axle with a large inner diameter.
Then it would be possible to therein withdraw the clevises and the pitch bearing.

mbouwer · « **Reply #189 on:** March 12, 2019, 08:17:36 AM »

Found 2 scrapped bearings. I want to use the inner rings (inside diameter 110 mm)

mbouwer · « **Reply #190 on:** March 12, 2019, 08:23:54 AM »

In one of the rings I added a mounting ring.
And after that I grinded raceways in the sides for the new 4 mm balls.

SparWeb · « **Reply #191 on:** March 12, 2019, 11:52:51 PM »

Making your own bearings? This is a very unorthodox thing to do.
You have proven that your fabrication equipment is good, but making bearings requires a very high sophistication.
Are you able to answer my many questions?

Did you machine the races of these bearing? Why did you choose to do that?
Guessing by what I see in your lower picture, is there a weld in the outer race?
How did you grind the races?
How will you re-harden them?

I will start with that - I have many more questions still not yet asked.

mbouwer · « **Reply #192 on:** March 13, 2019, 07:36:43 AM »

Your questions are welcome.
A bearing with a larger inner diameter brings advantages. But it must not become too heavy.
The races were grinded on the lathe.
I do'nt know if I have to re-harden them since I do'nt know if the material become too hot.

Frank S · « **Reply #193 on:** March 13, 2019, 10:24:28 AM »

Sparweb I am beginning to understand his methods to this build. It is a proof of concept model not meant to fly for a long life but to be used to see where certain components may further optimized or have additional structural strengths added. Finding a pair of large bearings near to the size he believes would allow the build to continue without having to search for and buy new but rather regrind them to suit his intended design characteristics even should they possibly have shortened service life would be acceptable.
At least that is what I think he is doing.
I know in the past I have had to take two different bearings and re ground the profiles to accept different sized balls then used the inner of one and the outer of another to achieve the size I needed when I couldn't locate the proper replacement bearing at the time or wait until one could be ordered,to put a machine back in service knowing it may be temporary

SparWeb · « **Reply #194 on:** March 13, 2019, 10:32:35 PM »

Quote from: Frank S on March 13, 2019, 10:24:28 AM

It is a proof of concept model not meant to fly for a long life

That helps, thank you Frank. I can get off my soap box now.

The grinding is hard to see in the photos (and looked more like welds!) but this is a way that the camera can tell lies.
Given the care and attention you've dedicated to your other work, I have no doubt that you carefully ground them, too.
I am curious about how you'll keep the balls well spaced unless you can come up with a cage for them too.
If you're looking for ideas on ball arrangements, I think I've heard of special ball spacers, which might inspire some ideas, but I don't think I could find the link to the article again. Just a strange thing I read once and this reminded me of it again.

mbouwer · « **Reply #195 on:** March 14, 2019, 06:39:33 AM »

Wind power is booming and I find it a pleasure to shape windmill components. And I am always willing to show details.
As you can see in all my postings it is a development and a learning curve that I am going through. Hence the exchange of views with windmillfriends is pleasant.
The objective is to achieve a small and save functioning and reliable mill in my garden.

Mary B · « **Reply #196 on:** March 14, 2019, 03:07:17 PM »

I have seen nylon used as spacers for low rpm uses like this(Antenna rotors use a nylon cage for example), this is one from a Ham IV antenna rotor(medium duty rotor)

Quote from: SparWeb on March 13, 2019, 10:32:35 PM

Quote from: Frank S on March 13, 2019, 10:24:28 AM
It is a proof of concept model not meant to fly for a long life

That helps, thank you Frank. I can get off my soap box now.

The grinding is hard to see in the photos (and looked more like welds!) but this is a way that the camera can tell lies.
Given the care and attention you've dedicated to your other work, I have no doubt that you carefully ground them, too.
I am curious about how you'll keep the balls well spaced unless you can come up with a cage for them too.
If you're looking for ideas on ball arrangements, I think I've heard of special ball spacers, which might inspire some ideas, but I don't think I could find the link to the article again. Just a strange thing I read once and this reminded me of it again.

mbouwer · « **Reply #197 on:** March 15, 2019, 07:20:49 AM »

Why not mounting the 4 mm balls side by side.
Many balls give a low surface pressure.

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Author Topic: axial generator with lamination core (Read 114374 times)