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Author Topic: Dia. Mag. Alternator  (Read 138422 times)

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #255 on: September 19, 2011, 01:59:22 PM »
Been clearing space, deconstructing old stuff scavenging what I need to
build the new stuff.  Got the groove cut in the piece of 1.25 inch square
pine to be the meat of the right angle brackets.  Then made some triangles
with 3/8" plywood...
http://scientilosopher.blogspot.com/2011/09/groovy-brackets.html

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Re: Dia. Mag. Alternator
« Reply #255 on: September 19, 2011, 01:59:22 PM »

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #256 on: October 02, 2011, 09:18:11 AM »
Building the pedestal for the test plate.  I mitered some
square pine stock for a frame.  Then glued and screwed
the pedestal base together.  Cleaned up the groovy
brackets, and glued them together.  Then test fit the
motor/alternator plate.  Looks good so far...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #257 on: October 02, 2011, 11:13:06 AM »
Aqua-VI

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #258 on: October 03, 2011, 12:59:24 PM »
Mounting the motor plate here, and then adding the electric controls
for variable voltage and current...

Offline energia9

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Re: Dia. Mag. Alternator
« Reply #259 on: October 03, 2011, 03:35:45 PM »
Aqua-VI

i love your work Z Monkey, you are doing continous work on your idea, this is what overunity people should all do... keep up the nice work my friend....
what are your future goals?

peace

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Re: Dia. Mag. Alternator
« Reply #259 on: October 03, 2011, 03:35:45 PM »
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Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #260 on: October 22, 2011, 06:28:38 PM »
Thanks energia9,

I wish I had more time to devote to my projects.  Unfortunately I have many things to maintain, and over the past few weeks I have had to spend most of my time on my day job.  I am working towards making an actual product that I can sell, and turn that into a business.  Then maybe I can shed the day job.  This sounds simple enough, but it is a little harder than you might think.  The day job parallels my projects, so this is good in that the experience I gain there benefits my projects, and in my spare time at work I can work on my projects.  Slow progress is still good progress...

So, the Test Platform is coming along good.  I built a speed control board for controlling the voltage to the motor which is driving the DiaMag8 Alternator.  I want to overdrive the motor, so I built a 24 volt battery pack.  Then I can adjust the voltage going to the motor with the speed control board.  The motor is rated at 12 volts and I am wanting to take it up to about 18 volts to hit my target speed, which is 3600 RPM.  The label RPM is 2350 at 12 volts.  The pulley ratio is 1 to 2.3, so when the motor is turning 3600 RPM, the Alternator will be turning at 8280 RPM.

My initial design for the speed control didn't quite do what I wanted, and I had to rework it.  Originally I wanted a voltage control and a current control.  But the voltage regulator wasn't providing enough current and the current control just didn't work.  So I reconfigured the voltage regulator to drive the current regulator directly, and now only have one control.  At least now it works, schematic below.

Then there are the battery issues.  Big Sigh!  I had the D Cell battery holders and a bunch of D size batteries that I have used for projects in the past.  These batteries have been in the shop for years, and been used for various other projects and in flashlights, and all of them are mixed, unknown state.  So I get the battery pack put together, go test it, flip the switch and watch the voltage take a dive.  Uulgh...

There are 16 D cell batteries in the battery pack.  i had a thought to go buy new batteries.  I did test all the batteries and weeded out a few dead ones, but even then the battery pack would just barely turn the motor.  At this point I was really frustrated, and just walked away from it.  The next day I found a 12 volt 7 Ah sealed lead acid battery that I could use for testing.  So, after reconfiguring the battery I finally got the motor turning.  I am driving the motor directly with the lead acid battery because the voltage is too low to use with the speed control board.  Ultimately I want to replace the D cell batteries with new ones, and then I can use my speed control.

On to the next problem.  At 12 volts the motor is spinning at 2350 RPM, time the pulley ratio of 2.3, is 5400 RPM.  The alternator develops about 18.5 volts AC, open circuit.  This part is good.  The bad part is at this speed the centrifugal force on the aluminum rotor is causing it to stretch, and it is crashing into the stator.  This is extremely frustrating.  I regret using a soft metal on the stator.  I didn't have this problem before with the solid Neodymium rotors, they are very hard, and don't stretch much when taken to extreme RPMs.  So, now I have to take apart the DiaMag8, again, and try to increase the clearances around the rotor without damaging the windings.  Without the windings this would be relatively easy, just a mater of filing down the stator.  But doing this with the windings in there is kind of precarious.  Worst case scenario if I damage the windings is I will have to unwind and rewind the stator.  So, hopefully I can be intrepid enough to increase the clearances without damaging the windings...

So, getting there, very slowly...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #261 on: October 23, 2011, 01:15:46 AM »
Doh!

Found the problem...

I was all busy filing down the stator, and not making a difference.  I was looking at the rotor very carefully while it spun up.  I could see a definitive point where the rotor jumped up an hit the stator.  That's weird, why doesn't it expand gradually increase in diameter.  Why does it suddenly jump up like that.  Then I started inspecting the rotor.  The damn epoxy failed.  The magnet are loose, and when the centrifugal force exceeds the magnetic attraction the magnet pops out and hits the rotor, making a nasty grinding sound...

Forksocks!  This is exactly why I typically secure the magnets using hardware and not glue....

Aaargh!  Well, now I know.  The smooth surfaces of the metal make for a not so good bonding surface, and the epoxy was the 5 minute variety, so there is the very good chance the epoxy would fail.  Damnzit!  These radial segment have no other way to secure them.  No screw holes...

Looks like I'll have to use to industrial epoxy to get them to stick...

Well, at least I found the problem...

BTW, killed the Dremel Tool grinding the stator.  Yay!  Gotta buy another tool...

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Re: Dia. Mag. Alternator
« Reply #261 on: October 23, 2011, 01:15:46 AM »
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Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #262 on: October 23, 2011, 06:56:45 PM »
Still having problems with the rotor, but I did get them to stick long enough to run a test.  I had found that two of the magnets had popped loose.  Eager to test, I glued the two loose magnets back on using the same 5 minute epoxy.  While I was testing another magnet popped loose.  But I did get to run it, get a video, and finally start to realize the potential of DiaMag8.

For this test I am hooking up the motor directly to the 12 Volt battery, no speed control.  The output of the alternator is around 15.5 Volts open circuit.  Then I am using a 1 to 10 step up transformer to boost the voltage up to where I can power a 120 Volt bulb.  The output voltage of the transformer is 151 Volts open circuit, and around 71 Volts loaded with a 10 Watt 120 Volt bulb.  While the test was running another magnet popped loose and crashed into the stator.  Uulgh, so I need to rework the rotor, again...

Here's teh video...

http://www.youtube.com/watch?v=KsOjhwYOQ4U&feature=channel_video_title

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #263 on: October 29, 2011, 03:19:20 AM »
OK, reworking the rotor...

First I had to break off all the magnets.  Not surprisingly this was not too difficult.  The cheap 5 minute epoxy was not too hard to break.  I used a chisel and the palm of my hand to break the magnets loose, blech...  Then I needed to remove the failed epoxy from the magnets and rotor.  Mainly I was able to do this with my fingernails, double blech...

I figured I could increase the adhesion on the rotor by roughing up the surface of the rotor.  So, I chucked up the rotor in the drill press, and used a coarse rasp to rough it up.  This action also removed any old residual epoxy from the rotor.  The process also removed some aluminum from the rotor.

This time I am using an industrial grade marine epoxy.  Its viscosity is greater, and hopefully the adhesion is greater.  I reassembled the rotor clamp jig that I used before to hold the rotor while I am gluing the magnets.  Its basically just a couple of scrap 2x4s clamped to the bench.  Then I used some cable clamps to hold the ends of the shaft to the 2x4s.  I get all the magnets lined up on the fridge to help the process when I am sticking the magnets to the gooped up rotor.  The epoxy working time is 50 minutes for this variety, so I am not too worried about time.

Then the epoxy gets mixed and schmered evenly across the outside diameter of the rotor.  Its a good idea to get the epoxy as evenly distributed as possible to get all the magnets coated evenly.  Then I start applying the magnets, taking care to get them in order, NSNSNSNS.  The magnets will let you know if they are in the wrong order because they will not want to sit next to each other if you get like poles next to each other accidentally.  After placing the magnets I spend a while cleaning the excess epoxy off the rotor and magnets.  This epoxy sets in 50 minutes, but I am going to let it cure for a full 24 hours before I spin the rotor.  Just trying to get a full, solid cure before I put any stress on it.

Can't wait till tomorrow night...
« Last Edit: October 29, 2011, 04:09:06 AM by z.monkey »

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #264 on: October 29, 2011, 04:45:51 AM »
Here is a better detail view of the 2nd Rotor Assembly...

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Re: Dia. Mag. Alternator
« Reply #264 on: October 29, 2011, 04:45:51 AM »
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Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #265 on: October 30, 2011, 11:19:27 AM »
The new rotor is working good...

http://www.youtube.com/watch?v=2AlMPDWqAMA

 

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