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Bryan's 4Kw motor Conversion Part 2 The testing
ruddycrazy:
G'Day Guy's,
Well finally got that cable so now installing the Gimp so I can resize them so they will come in the next post.
Got thinking about the test and how to get the right speeds for simulating the wind, now as my 16hp Listeriod runs around 900 rpm I thought well a 2:1 reduction can go the lay shaft and at 450 rpm the beast should be in it's prime. I knew i had some step pulleys off old drill press's so dug them out and found one was still connected to the AC rotor shaft duly pulled off the pulley and bearings and decided well as the step pulley end of the shaft is keyed and it is a neat fit to use the rotor shaft. Well it was a bit of fun cutting off the rotor and in the end had to do 2 cuts opposing so I could crack it open to get the shaft out. Sure enough it wasn't going to press out as the shaft had a parallel knurl where the rotor was so the rotor would of been built on the shaft.
As the 2 step pulley are different diameters this does play into my favour where I worked out the reduction would give me 255 rpm which is just above cutin and in the centre pulleys both are 120mm so that will make 450 rpm. The other one to use is about 740 rpm so that will be I reckon close to saturation point so by using this rpm as the set point that disk brake I'll be putting on can be tuned.
Cheers Bryan
Edit: Trying to upload pic's but on the preview it's just a white box and no pic
ruddycrazy:
G'Day Guy's,
Well this pic is the planned site where the 2Kw conversion is going which is on top of the hill to the right, walked outside this arvo and just had to take that pic.
Ok here is a pic of the conversion and as we can see I did make the output shaft nice and long so the disk brake can be attached
Here is a pic of the front of my shed which I took when I was marking out the 6mm plate for the motor mount and the plate, now in the corner is that 16HP engine I will be using for the testing and beside that bench where that 3Kw inverter is sitting which is the one I got custom made in Taiwan back in '05 and when I contacted them about a schematic they said the never made that model. got an email a few days later and it turned out the enignear that I dealt with ended starting his own business making them and made a killing on ebay. That battery beside the table is a 24 volt 735AH forklift battery that has taken on a new life in my shed and just loves this wild weather in winter.
More pic's to come when i get that pulley setup on the go and I am thinking of making pattern so I can machine up a variable speed drive so input speed in and variable to the max so for testing out conversions will be a breeze.
Cheers Bryan
ruddycrazy:
Well why I'm on a "rant" here it goes
As the Beast will serve us a a major power source for a long time it does need a brain so I'm going to drill hole in the rear of the shaft and epoxy in a 3x3mm neo and put in a hall effect sensor so I can measure the rpm of the turbine.
A wind speed meter will be made which can connect well under the blade sweep to get a true reading so data can be collected about wind speed and rpm.
A couple of DS18S20's to monitor the motor temp and the current temp will be put in and a setup so wifi can be used to transmit the data.
Maybe a few guru's on electronics can pipe in for the best option to use and a couple of 5 watt panels attached to the housing can charge the battery that powers the brain.
Now for the disk brake the amount of fluid needed to close needs to be done as I think a decent solieniod I can make can do the job when over speed conditions come into play.
Many years ago I documented this on another forum and I lost all the pic's of the build so if any member can access that thread and tranfer the pic's over it will make my day.
The true test on the 16 HP motor will determine what the thickness of wire is needed for the cable run and I am thinking that pattern can make for a saleable item where one does need to test RPM of the conversion they made.
As Oztules said this is one bullet proof design from a Ozzie now I do take notice and I hope that Mexican is still walking and you know the old saying anyone south of you in Oz is a Mexican.
Now and when this 4Kw starts to work I do think back about this great bloke that got me line hook and sinker that it won't have a tail to put a name on it
RIP Zubbly the knowledge you gave me and that dream I had about getting that 4Kw in the air was real but in a dream.
Now if I can I add if I ever get to sell one of my motor conversion projects I will with a hand of contacts send 8% of the sell price to the family
"end Rant"
kitestrings:
Nice pics! I like the 'rainbow's end', and I like that generator.
Some (many) years back I worked on downwind, AC induction wind turbines. We had a single-phase model that relied on an rpm pick-up/sensor as part of the control scheme. I believe it was to allow the rotor to free-spin below cut-in and then connect, in synch with the AC main; in theory anyway. It never worked well. We just always had a battle getting clean rpm feed to the controller. I know the cable had to be shielded, grounded, etc. Others may know more what the obstacles are and how to overcome them.
On our axial we used an rpm sensor designed by Brian Smith, who used to frequent here. It works off the frequency of one of the AC leads. Seems to work well.
So, you are using a disc brake, but I didn't follow - does/will it have some sort of hydraulic operation to activate it?
Mary B:
Key to using a hall effect sensor is shielded cable that is only grounded at the electronics end of the path. Ground both ends you can set up a ground loop that introduces noise. How my antenna rotors work.
Next step up is use an encoder but they cost 8 times a hall effect sensor! But they are very very accurate. They are an option on the rotors I use and offer .1 degree accuracy and use an absolute encoder that remembers its last position after a power loss.
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