Author Topic: gear box study  (Read 8255 times)

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mbouwer

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gear box study
« on: February 08, 2018, 08:21:17 AM »
To power a generator with the right number of  r.p.m.
I want to try to make a two stage gear box.

hiker

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Re: gear box study
« Reply #1 on: February 08, 2018, 02:28:48 PM »
https://www.fieldlines.com/index.php/topic,146180.msg999841.html#msg999841            Search box. Chris Olson  gear box             Lots of info their...he built quite a few turbines..
« Last Edit: February 08, 2018, 02:32:58 PM by hiker »
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mbouwer

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Re: gear box study
« Reply #2 on: February 08, 2018, 05:30:09 PM »
Chris Olson's writings always had my very great interest.
This is new inspiration.

SparWeb

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Re: gear box study
« Reply #3 on: February 08, 2018, 11:08:26 PM »
Well, Chris never made them that big!

How big is your turbine?  Just trying to estimate the power, torque and speed are the first steps before knowing what you need in a gearbox - or whether one is necessary... and that depends on the choice of generator you make.
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
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mbouwer

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Re: gear box study
« Reply #4 on: February 09, 2018, 09:24:16 AM »
In the first place it's only a study how I can weld a suitable gear box for a small windmill using scrapped gear wheels.
Now the gear ratio is 12.56  ( 4 and 3.14 )

SparWeb

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Re: gear box study
« Reply #5 on: February 09, 2018, 08:55:06 PM »
I see.
Make sure to consider that with a 12.56:1 speed ratio, you also get a 1:12.56 torque ratio.
This means that the friction in the alternator bearings, and any other slight resistance, will be multiplied by 12.56 and preventing your turbine from starting.
You can counteract this with your variable-pitch blades, of course. 
This is getting pretty complex.
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
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mbouwer

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Re: gear box study
« Reply #6 on: February 10, 2018, 08:10:03 AM »
Thanks Sparweb,

The kind and the way of lubrication will also be important I think.

The main axis. With double walled composition I try to save weight.

Rainwulf

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Re: gear box study
« Reply #7 on: February 10, 2018, 08:28:37 AM »
You must use roller or needle bearings for your main axis. The wind puts a LOT of axial and rotation force on them. That's why the volvo 740 front ends are so popular. Made super tough.

mbouwer

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Re: gear box study
« Reply #8 on: February 10, 2018, 03:07:53 PM »
Found ball bearings 89-50 width 20 and 62-35 width 14 mm.

mbouwer

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Re: gear box study
« Reply #9 on: February 11, 2018, 08:58:56 AM »
The internal assembly in the gear wheel to fit on the main axis.

mbouwer

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Re: gear box study
« Reply #10 on: February 12, 2018, 09:23:30 AM »
Spigots in 3 key ways ensure that the gear wheel does not slip on the shaft.

mbouwer

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Re: gear box study
« Reply #11 on: February 14, 2018, 09:36:37 AM »
The first driven axle has 15 teeth and bearings 35-17 width 10  and 40-17 width 12 mm.
Now shaping the casing.
« Last Edit: February 14, 2018, 12:54:15 PM by mbouwer »

Rainwulf

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Re: gear box study
« Reply #12 on: February 15, 2018, 07:06:37 AM »
You are using second hand stuff for this? I would have gone for helical if you had the choice.

Straight cut gears are gonna be NOISY

mbouwer

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Re: gear box study
« Reply #13 on: February 15, 2018, 07:44:08 AM »
Rainwulf,

You are right, but I thought the first stage straight cut wo'nt spin so many revolutions and will not be so noisy.
The second stage is helical cut.

Interior vieuw of the top and bottom part of the casing.
« Last Edit: February 15, 2018, 07:48:53 AM by mbouwer »

mbouwer

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Re: gear box study
« Reply #14 on: February 16, 2018, 06:21:15 AM »
The first stage. Gear ratio 1:4
The two inspection openings will be closed with a small flap.

SparWeb

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Re: gear box study
« Reply #15 on: February 17, 2018, 12:41:00 AM »
Did you sand-cast the cases?

Does the hi-speed shaft need a keyway?

I also can't help asking about the low-speed shaft - threading a driveshaft is not common practice.  What couples to it?
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca

mbouwer

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Re: gear box study
« Reply #16 on: February 17, 2018, 06:35:31 AM »
Thanks for asking. It looks a bit like sand-casted. But I shaped the cases mostly from 2 mm steel sheet. The bearing houses are machined out of 5 mm thick steel rings.

On the hi-speed shaft I have to make some coupling to drive the second stage.

At first I had the intention to lock up the bearing with the threading, but later on I welded half a dozen cams on the edge of the bearing house and I removed the thread.
« Last Edit: February 17, 2018, 06:44:29 AM by mbouwer »

XeonPony

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Re: gear box study
« Reply #17 on: February 17, 2018, 09:07:51 AM »
I'd be looking to make a planetary or pseudo planetary gear system, they do that by putting another gear in then combining them on the out put stage to balance the torque over three spots of the main gear.
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mbouwer

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Re: gear box study
« Reply #18 on: February 17, 2018, 10:43:22 AM »
The point is that you need a hollow main shaft for blade pitching.

SparWeb

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Re: gear box study
« Reply #19 on: February 17, 2018, 10:57:07 AM »
mbouwer,
Shaping sheet-metal - That's interesting!

Would you be interested in sharing some pictures and info about your work tools here? https://www.fieldlines.com/index.php/board,46.0.html

PS, the image posting guidelines are more relaxed now, so if you are doing a lot of work to crop and resize your images, hopefully this will make it easier for you.
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca

mbouwer

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Re: gear box study
« Reply #20 on: February 18, 2018, 05:06:04 AM »
Sparweb, that I will consider.

Top view of the gear box (stage 1) + the components I would like to add.

mbouwer

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Re: gear box study
« Reply #21 on: February 19, 2018, 07:00:25 AM »
Can this direct drive washing machine motor WMD-300C2 be used here as a generator?

hiker

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Re: gear box study
« Reply #22 on: February 19, 2018, 12:55:27 PM »
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hiker

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Re: gear box study
« Reply #23 on: February 19, 2018, 01:01:20 PM »
Enter....motor to generator ....that should take you to a number of posts...go back to main page for that...otherwise nothing will show....
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mbouwer

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Re: gear box study
« Reply #24 on: February 20, 2018, 06:23:07 AM »
It is the search for a generator that I can use in combination with this transmission.

The third axle with bearings 52-20-15 and 47-20-14

mbouwer

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Re: gear box study
« Reply #25 on: February 21, 2018, 08:16:44 AM »
Axle no. 4 with bearings 37-12-12 and 35-15-11

mbouwer

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Re: gear box study
« Reply #26 on: February 22, 2018, 07:52:44 AM »
Shaping the casing for the second stage.

mbouwer

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Re: gear box study
« Reply #27 on: February 23, 2018, 07:41:36 AM »
The rough bearing housings for axle no. 4

mbouwer

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Re: gear box study
« Reply #28 on: February 26, 2018, 08:00:58 AM »
Now the casing for stage no. 2 is ready.
I wonder if there are more people on the forum who want to make a design with a gear box.
« Last Edit: February 26, 2018, 08:07:54 AM by mbouwer »

mbouwer

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Re: gear box study
« Reply #29 on: February 27, 2018, 06:57:24 AM »
The assembled stage no. 2

Bruce S

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Re: gear box study
« Reply #30 on: February 27, 2018, 08:40:10 AM »
May I ask a small favor?
Could you maybe put a ruler or some type of scale along side? This would help even me get an idea of how large or small these devices are in relation to other objects.

Thanks in Advance
Bruce S
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mbouwer

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Re: gear box study
« Reply #31 on: February 27, 2018, 12:15:41 PM »
You are welcome.

SparWeb

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Re: gear box study
« Reply #32 on: February 28, 2018, 12:21:26 AM »
Thank you, that helps me, too.
I'm looking forward to Stage 2!
No one believes the theory except the one who developed it. Everyone believes the experiment except the one who ran it.
System spec: 135w BP multicrystalline panels, Xantrex C40, DIY 10ft (3m) diameter wind turbine, Tri-Star TS60, 800AH x 24V AGM Battery, Xantrex SW4024
www.sparweb.ca