Life's Little Setbacks

[ghurd]

Nice tight fit with the calipers.

A bit of tape to protect the curved magnets.

But too much tape I guess.

Seemed like a good idea at the time.

Too funny.

Between the magnets, the tape, and the stickiness...This is really stuck!

G-

[willib]

how big is that motor, rotor?

attach the motor housing to a bench , attach the shaft & rotor to your car bumper , and back up?

where did i hear that before??lol

[ghurd]

It's a monster.  1/6HP.  The rotor started at 2.77" OD.

Very close to the same as a box fan, but much thicker.

Floor jack, truck bumper, couple 2X4s... It's a 2 person job, no help!

[willib]

2x4s will do it , only one person needed,

fix one  2x4 on a table lying flat

attach another 2x4 to one end (pivot point)

attach stuck alternator between the two

and pull

[wind pirate]

100 feet of rope tied to the rotor. 20 lb weight tied to the housing. 110 foot cliff. Throw, repeat as needed

[ghurd]

Dude!  This puppy is big-time stuck!

Repeat, repeat, repeat...?

Maybe try a 50lb weight?  

Maybe tie a 110' cliff to the housing? Then throw it off a 220' cliff?

Hmmm...

Bigger fun than usual!

[vawtman]

Ghurd i cant beleive a pro like you would allow your Shaft to get stuck.Lol

 

[Norm]

  Hold the housing over the top of a fence post

and pound the shaft down onto the top of the post.

        ? ( :>) Norm.

" a fine mess you've got us into now ...Ollie !"

(....or something like that.)

[Countryboy]

Lay 2 2X4's side by side suspended over sawhorses or something solid.

Have the case rest on the 2X4's, with the magnet rotor dangling between the 2X4's.

Put a block of wood on the end of the magnet rotor shaft, and smack it with a BFH.  (A BFH is a Big F'ing Hammer.)  Drive the shaft out the way it entered.

Make sure you use a block of wood between the hammer and the rotor shaft to avoid damaging the shaft.

If you don't like that idea, see if you can find a solvent that will eat tape, without damaging the insulation.

[Countryboy]

The above advice is assuming you do not have access to a hydraulic press.  If you have access to a press, use the press instead of 2X4's.

If you have a really big bench vise, you could use a bench vise instead of a press too.

[stephent]

Lighter fluid on the tape.

 (3 n 1 oil) on the tape.

let it/them soak for a bit, dissolves the tape sticky stuff.

makes it slippery.

pull or knock out easier.

 

[ghurd]

OK, its out.

I set the rotor axle on a short piece of pipe, pushed down on the housing.

Slow and steady, moved 1/2", then it was free.

I should have seen it coming...

The magnet ID is a little larger than the rotor OD, making the sides of the magnets above the rotor, and a larger OD.  If anyone can follow that.

Meaning the caliper probably rocked the magnets down and read a smaller total OD.

The tape just made it worse.

No damage except for scratching the magnets a bit more than they were.

The magnets need 'some adjustment to their size' anyway, so scratches don't matter on this one.

G-

[coldspot]

LOL!

Did the same almost with 2HP 3ph.

Tried the pop bottle shrink wrapping trick,

the plastic thickness was to much for what the guy with the lathes had left me for clearance between magnets and Lam T's.

"Stucker than muck"!

Had a tire off my toyota truck and placed the edge of the motor can just over the inside of rim for center hole in rim, used a couple metal parts to let can balance by it's self.

 Whacked it with a 2x4 and it came out without any damage to anything, magnets, motor can or rim.

 Then I tried to assemble without the wrapper and it fits very closely.

Tuff being human isn't it!

LOL

[dinges]

1/6 HP? OMG. It's a powerhouse!

You ill? Forgot to take your pill?

[ghurd]

I took my pill. A whole one.  

That's why I figured it would be OK do try something this big...

Because I don't expect it to work too great!

Zubbly's math, 0.572^3" of magnet x 150W = 86W... if it's well made... and it ain't.

But I had everything here, and wanted to try a 6 coil 4 magnet 3-ph that had all 3 phases.

Without my pill, I believe it might work better than 150W/ cubic inch, if done right.

G-

[dinges]

Ghurd,

Have a look at what -real- men play with:

http://www.anotherpower.com/gallery/dinges/3hp_10hp_together?full=1

I should have added my 130W (1/6hp) conversion in that picture as well. But, that would only give you an inferiority complex or make you feel uncertain.

Talking about feeling uncertain; I'd better re-tighten that gas cap...

[ghurd]

Shiny shoes?  Fan motors?

Dude, this is a mafia and steel mill town!

No pelvis pieces? No DNA from Jimmy Hoffa?

Then its just another old motor...

A loose gas cap can't cause an explosion? Can it?

Hehe

[ghurd]

A bit of progress on my "like a box fan motor, but thicker".

2 original #29s? (curved magnets, but not nearly as strong as NTL's #29s), cut in half, meaning 4 magnets on the rotor.

The "stuck" photo above has 4 full size magnets.

The air gap is now far too large.  Maybe 0.070" / 1.6mm?

I made a miscalculation earlier.  It may go back to full size magnets.

Testing 1 phase, consisting of 2 series factory wound coils.

Spinning with Vice Grips with 1 finger, about 140RPM(?) goes about 2.4VAC.

Ohms per phase?  No idea. It will be figured out later.  The "Free Meter!" reads 0.7 ohms per coil, 0.9 for 2 series coils, 0.3 ohms with only the meter leads.

Isc well over 2A with very little effort. The force required for rotation is not noticeably different than open circuit (a far better sign than most of my stuff!).

Magnets are at 1, 4, 7, & 10 o'clock.

The shunts are not removed.

The pizza boxes were intended to catch solder drops. It didn't work. And they DO catch on fire!  

My wife didn't see that. :-)

G-

[dinges]

Hi Ghurd,

The magnets you use; are they Neodymium ones? I suspect they are, since in a previous reply you mentioned using Zubbly's rule (150W/cubic inch), giving you an expected output (if done perfectly) of 86W.

If the magnets are neos, then 1.6 mm airgap doesn't sound excessive to me. Am curious as to what other people's ideas are on this matter. The 130W (1/6hp) conversion I'm working on now has an airgap of 2.5mm (at the center of a magnet). I'd rather have had a little bit less, but alas.

That vise; do you need it to overcome the cogging?

The coils look a bit toasted to me. That blackened appearance doesn't look good. Maybe do a rewind?

Nice little conversion. Then again, compared to your previous VCR-motor windgennies and the steppers, it's a monster...  

[ghurd]

Hi Peter,

The magnets? I can't say if they are neo.  They are the weakest neos that I ever saw, or something stronger than I expect for non-neo.  At the least they are some type of 'rare-earth'.

The magnets in it now are not quite cut like they could be.  Yea, I screwed up again. Write it down, it's your last chance to catch me with a mistake!

The gap is not as bad as it could be, just a lot more than I expected.

Ed's results in these matters make me believe the gap should be much less.   My results reinforce the belief.  The space is available.  It looks like there could almost be clearance even if the bushings wear completely through!

The `vise' is a translation thing.  Vice Grips © is a brand of locking pliers.  I locked them to the motor shaft.  They simply add a fixed lever to the shaft so it can be turned with 1 finger.  Much like 1 blade would be turned with 1 finger.  They are black and visible in the 2nd photo.

Why do you insist I rewind a motor?  If you can't move it, paint it. The color is grey paint that came through the vent holes.  The wire is fine (I hope) and the wire color is accurate where the tape was removed from each coil.

It is a monster!  1/6 HP!  Consider the possibilities...

-I am almost ready to use a bigger battery.  I might move up to 17AH.

-I need to call the electric company so they can disconnect my service.

-The LED light can be changed to CFL.

-The tower needs increased 25% in height, to 2,5 meters.

-The blade diameter needs increased to a full meter. Maybe more!

-It can power my VCR, during a hurricane.

I still have a feeling it will make over 100W