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Author Topic: Power of Commutators  (Read 1286 times)

Offline floodrod

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Power of Commutators
« on: March 22, 2023, 03:24:54 PM »
I am thinking old fashioned commutators may be the way forward.  This thread will propose reasonings, examples, and document some past and future commutator builds.

1. Adams motor- he used a commutator
2. Clemente F-  Used a Commutator
3. Newman Motor- Used a Commutator
4. Tesla's motors
And I am sure countless others..

Sure, one could say they used commutators because modern electronics were not available back then (in some cases)  But perhaps commutators are better even so..

1. They usually will not blow up easily like FET's and other electronics. 
2. You can use real current and low resistance coils
3. They work in reverse
4. Less loss??  (depending on the brushes)
5. No need for sensors, PWM controllers, and Logic power.
5.  More reasons???

My first motor I ever build had a homemade commutator to switch DC polarities..  Boy was it rough running.  LOL..  But it ran..  https://www.youtube.com/watch?v=0lHw4XlHBPc

Later today I plan to start a new related project to make a DC to AC commutator.  Actually more like a mechanical brushed inverter to test setups with. 

I will update if anyone's interested in the results.



Offline Thaelin

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Re: Power of Commutators
« Reply #1 on: March 22, 2023, 04:34:56 PM »
  That starts off sounding just like a dynamotor of the 40's. Had two commutators one each end. One for the motor and one for the HV gen side for the electronics of the day. You know, tubes, valves what ever you call them. 28v aircraft dc to 125 v ac 400hz.

Offline synchro1

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Re: Power of Commutators
« Reply #2 on: March 22, 2023, 06:44:55 PM »
A limit switch with this capability is a good idea :

EDIT-  Resized pic.  Please keep pics within size limit
« Last Edit: March 23, 2023, 03:24:43 AM by floodrod »

Offline floodrod

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Re: Power of Commutators
« Reply #3 on: March 22, 2023, 07:31:29 PM »
  That starts off sounding just like a dynamotor of the 40's. Had two commutators one each end. One for the motor and one for the HV gen side for the electronics of the day. You know, tubes, valves what ever you call them. 28v aircraft dc to 125 v ac 400hz.

Kinda, but with no step-up / coils..  What you put in is what you get out.

Synchro-  Here is a similar one I made like your post.  A little polarity flipper that uses a passing magnet or a pulsing electromagnet..  I called this one "Sparky" for obvious reasons..  It was a little too crude for practical use and required alternating magnetic field to operate, but it did run my motor fine..

The one I am starting now I want to work off simple rotation and be solid with proper brushes for reliability

Offline floodrod

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Re: Power of Commutators
« Reply #4 on: March 22, 2023, 08:24:42 PM »
And here is another one I made for 1 way pulsing an Adams motor.  This one worked pretty good except the heat started to melt the plastic. And I didn't take the time to make a proper brush setup.

It ran fine-  https://www.youtube.com/watch?v=VOWewgbJlaM

My new one I have a plan for the surface so it doesn't melt the plastic.

Offline Dog-One

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Re: Power of Commutators
« Reply #5 on: March 22, 2023, 10:53:45 PM »
What I'd like to see someone make is a commutator using good
ol' fashion mercury.  Gravity plays-in obviously, so the contacts
must be on the bottom.

Offline floodrod

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Re: Power of Commutators
« Reply #6 on: March 23, 2023, 03:16:19 AM »
What I'd like to see someone make is a commutator using good
ol' fashion mercury.  Gravity plays-in obviously, so the contacts
must be on the bottom.

Would be cool..  Less friction..

Update-  got the commutator made.  Looks decent.  Used JB-weld Steel-Stick to fill in the gaps and prevent melting the plastic.  Steel Stick is Non-conductive, stands up to 900 PSI and between 350-450 degrees temps. Also got the input brush holder done..  Took several prints of course....  Printing the output AC brush holders now.  Probably take a few re-do's to get these right too.

Pretty simple design. But I think it will do what I am looking for.

Offline floodrod

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Re: Power of Commutators
« Reply #7 on: March 23, 2023, 06:51:05 PM »
My brushed mechanical inverter works fine..  Alternating DC square waves from a battery with no circuitry.

It can definitely be improved, but good enough to use it as a test source..

See it run and the scope output---->  https://www.youtube.com/watch?v=vofne2-pNHE

Offline Thaelin

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Re: Power of Commutators
« Reply #8 on: March 23, 2023, 07:22:22 PM »
  The test will be the test if time on the brushes. How long can they hold up. The rotor of a small motor wired up to do the same thing will last longer in my op. But you have done what I tried and failed to do. Just graft an old motor to your system and wire the contacts to do the 50/50 if that is what you want. Can even make it faster if you use less segments.
thay

Offline floodrod

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Re: Power of Commutators
« Reply #9 on: March 23, 2023, 11:58:51 PM »
  The test will be the test if time on the brushes. How long can they hold up. The rotor of a small motor wired up to do the same thing will last longer in my op. But you have done what I tried and failed to do. Just graft an old motor to your system and wire the contacts to do the 50/50 if that is what you want. Can even make it faster if you use less segments.
thay

Thanks for the comment.  The commutator is nice and smooth like glass. and practically no sparking, so hoping it lasts the test of time.

Yes your proposed way is something to consider, but for now, I want to power the motor separately from a 2nd supply and not run the driving current through motor windings.  I would like to look at the source and know how much power my test device is utilizing not counting the power it takes to spin the commutator.

I had it running for about an hour total already (on and off) and the Steel-Stick Epoxy is working excellent..  I think steel-stick is an excellent choice for filling in commutators. 


Offline floodrod

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Re: Power of Commutators
« Reply #10 on: March 24, 2023, 01:03:25 AM »
Gonna make the 16 pole Clement Figuera Commutator next...

I just tried soldering pennies.  Get them hot enough and they solder fine..

Update- Here is the design and plan-  https://www.youtube.com/watch?v=nL8kCuGbyAk

Offline floodrod

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Re: Power of Commutators
« Reply #11 on: March 24, 2023, 02:40:40 PM »
Just updating in case anyone has some advice as I continue..

16x pre 1981 copper pennies
Steel-Stick track between pennies to absorb heat
Sand it smooth

Offline floodrod

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Re: Power of Commutators
« Reply #12 on: March 25, 2023, 02:31:11 AM »
What a PITA...

" We will add also a rotating brush which is always touching more than one contact."

Doah...  To accomplish this, I have no choice but to use 3 brushes on the contacts, + 1 brush to input the DC..  4 total brushes..

Guess that's why Clemente says " A brush or a group of brushes"..  Just hoping the computer fan has enough juice to spin with 4 brushes on it..

Other than that, the build is going OK..  Triple brush holder is printing now,  then need to design and print bottom DC input brush holder and a Top Bearing support..

Whatever...  I am determined to build this commutator now and test this device as specified..

https://www.youtube.com/watch?v=Hup2XlFNHf8

Offline floodrod

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Re: Power of Commutators
« Reply #13 on: March 25, 2023, 05:13:28 PM »
Woohoo..

Clemente Figuera commutator complete and working..  Had to improvise with the motor as the computer fan was not strong enough..

**  16 Contacts
**  Always touching at least 2 connection points

See it run-  https://www.youtube.com/watch?v=GstC0bMLXuU

I will probably start a new thread with info on the Clemente generator as I experiment..  This thread is just about commutators

« Last Edit: March 25, 2023, 09:28:39 PM by floodrod »

Offline floodrod

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Re: Power of Commutators
« Reply #14 on: March 25, 2023, 09:28:12 PM »
Running 12V Car Lights As The Load To Ensure The Commutator Is Working Right..

https://www.youtube.com/watch?v=XEGMTaEpCks

Not sure if the resistance is right, but seems it's working as it should~!