Author Topic: axial generator with lamination core (Read 114155 times)

mbouwer · « **Reply #264 on:** July 17, 2020, 12:37:00 PM »

Before I want to start working at a new generator on this axle above,
I want to mount the axial generator that I showed on page 6 of this thread,
on a new test rig and make a drive to test it.

SparWeb · « **Reply #265 on:** July 17, 2020, 09:24:11 PM »

Have you finished this test stand?

mbouwer · « **Reply #266 on:** July 18, 2020, 04:04:47 AM »

No I did not continue with that.
First I now want to make a variable drive.

mbouwer · « **Reply #267 on:** July 19, 2020, 09:21:57 AM »

Found this discarded motor. Variable from 0 to 2300 rpm and 900 Watt.
To drive the generator at the right number of revolutions I need a gearing.

SparWeb · « **Reply #268 on:** July 19, 2020, 08:23:42 PM »

Here is how I did my first generator test. The pulley on the generator's shaft kept the belt on the collar of the drill-press chuck. I was able to transmit about 200W this way, and the size ratio allowed for 100 - 200 RPM. It wasn't a lot, but I only wanted to test the lower end of the power curve anyway, and extrapolate up from there. This method did not have a torque arm, so I was unable to measure the mechanical power input. I could only measure the electrical power output.

mbouwer · « **Reply #269 on:** July 20, 2020, 02:51:59 PM »

Converting such a motor is a very interesting way to make a generator.
I have a few 380 motors here and I definitely also want to try it.

mbouwer · « **Reply #270 on:** July 21, 2020, 11:17:45 AM »

The shaft must remain free to make it possible to also test the blade adjustment in this test setup.

Therefore I mounted a V-belt "groove" against the front magnetic ring to drive the generator.

mbouwer · « **Reply #271 on:** July 22, 2020, 06:48:51 AM »

These gearwheels can form the right rpm speed ratio for my test set up drive.

SparWeb · « **Reply #272 on:** July 23, 2020, 01:02:45 AM »

Super!

I'm guessing 5:1 and 4:1 in those. That would take 3000 RPM down to about 150 RPM.

mbouwer · « **Reply #273 on:** July 24, 2020, 04:17:45 AM »

The final gear ratio will also be determined by the V-belt pulley.
I am trying to make a separate unit that can also be used on other test setups

mbouwer · « **Reply #274 on:** July 25, 2020, 08:21:43 AM »

Composing the shafts takes some time.

mbouwer · « **Reply #275 on:** July 26, 2020, 07:09:04 AM »

The pulley that I will mount on the gearbox.
This makes the total gear ratio about 50

mbouwer · « **Reply #276 on:** July 29, 2020, 04:14:16 AM »

My gear box is now ready and can be used in the test setup.

mbouwer · « **Reply #277 on:** July 30, 2020, 08:22:16 AM »

The generator must be able to tilt to determine the torque.
Therefore I want to attach this support ring to the stator frame.

mbouwer · « **Reply #278 on:** July 31, 2020, 08:49:16 AM »

This should become the frame for the test setup.

mbouwer · « **Reply #279 on:** August 01, 2020, 10:36:41 AM »

The motor speed control from reply # 267 does not work accurately under load.
That is why I want to use another motor. I have to make a speed variator then.

mbouwer · « **Reply #280 on:** August 02, 2020, 05:14:21 AM »

The drive motor is placed on slide rails. By tightening the V-belt I want to control the speed of the generator.

electrondady1 · « **Reply #281 on:** August 02, 2020, 07:03:49 AM »

wonderful fabrication skills mbouwer.

mbouwer · « **Reply #282 on:** August 02, 2020, 10:29:58 AM »

Bundling our knowledge and skills can bring us (wind) energy.

mbouwer · « **Reply #283 on:** August 04, 2020, 09:02:03 AM »

To measure the torque of the generator, it must be able to make a stroke, and therefore it is supported on 3 ball bearings.

SparWeb · « **Reply #284 on:** August 05, 2020, 04:04:07 AM »

Very interesting way to do this.

Be careful to apply torque in small increments when you begin to test. Observe deflections of the fixture - the deformations will grow as the load is applied. No way to know how much torque will cause the bearings to jump off the ring, but you certainly don't want a surprise!

mbouwer · « **Reply #285 on:** August 06, 2020, 08:48:03 AM »

I may have to strengthen the frame.

The torque measuring arm.
I want to measure the torque in the same plane as the drive and that is why I made this shape.

mbouwer · « **Reply #286 on:** August 07, 2020, 06:25:48 AM »

Under the torque measuring arm a console to place my scale on.

mbouwer · « **Reply #287 on:** August 11, 2020, 08:28:03 AM »

All parts combined into a test setup.
Measured starting torque of this generator is 9.4 Nm.

electrondady1 · « **Reply #288 on:** August 11, 2020, 09:19:51 AM »

wow. nice work mbouwer

SparWeb · « **Reply #289 on:** August 12, 2020, 01:09:02 AM »

Agreed.
It will be time to start making electrical connections, now.
IIRC, you have a large number of combinations to choose from.

kitestrings · « **Reply #290 on:** August 12, 2020, 11:46:52 AM »

Impressive, truly. The test set up looks like almost as much work as the build itself ;>] but valuable in the end.

Question: I assume the stated starting torque independent of the belt and pulley friction? How did you measure this mbouwer?

mbouwer · « **Reply #291 on:** August 13, 2020, 05:17:03 AM »

Sparweb,

Just a study how to build a test stand that maybe can also be used for other generators.That's how I see it.

Kitestrings,

The generator is driven by the motor and can actually rotate freely.
But the reaction arm prevents this rotating and presses on the scale.

kitestrings · « **Reply #292 on:** August 13, 2020, 03:19:34 PM »

Yes, I follow you, but if you are calculating, for example, the alternator efficiency, I would assume you need to look at power in vs. power out? I was just trying to understand how you account for the drive and pulley losses. Or, are you only comparing the electrical load on the generator relative the mechanical torque measure on the scale and moment arm?

mbouwer · « **Reply #293 on:** August 14, 2020, 05:01:41 AM »

So if I want to measure the losses in the drive, I also have to allow the motor to tilt.
With another moment arm attached to the motor frame.

bigrockcandymountain · « **Reply #294 on:** August 14, 2020, 04:21:10 PM »

Test setup looks good to me mbouwer. No wait, it actually looks amazing. I think it has more pieces than my whole turbine tower/turbine setup.

It will be interesting to see your test results.

Derek

mbouwer · « **Reply #295 on:** October 31, 2020, 10:03:21 AM »

Inspired by what I've been reading on the forum lately
I would also like to make a radial version.
This lamination core is 98 mm. inner diameter.

mbouwer · « **Reply #296 on:** November 01, 2020, 09:39:50 AM »

My intention is to make the outer diameter (now 175 mm) smaller until I have a bridge of roughly 10 mm.
Therefore I now have to make a mandrel to clamp the package.

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Author Topic: axial generator with lamination core (Read 114155 times)