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Author Topic: Dia. Mag. Alternator  (Read 179503 times)

Offline shylo

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Re: Dia. Mag. Alternator
« Reply #90 on: November 04, 2010, 09:12:33 PM »
Z looks good enough to give it a spin ....variable speed drill start slow and gradually increase......if you notice any rubbing or bad vibration just shut it down...........be a shame to do all that work and not at least do a trial run...........easy for me to say though .......is the play (sloppyness) where the bearings seat ,or between the shafts and the bearings themselves....or is it that the mags aren't perfectly balanced on thier shafts....that last one will be tough to do ....please keep us posted as you progress ....thanx ..shylo

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #91 on: November 04, 2010, 09:26:36 PM »
is the play (sloppyness) where the bearings seat ,or between the shafts and the bearings themselves?
Everything mounted to the shaft is extremely tight.  The clearance issue is where the bearing seats in the mounting plates.  The holes there are a little larger that the outside diameter of the bearing.  The bearing plates are aluminum so they are easily adjusted with my Blacksmith Hammer and a punch.

About running the thing, I don't have any problem running it like it is.  Although only the center magnet is going to spin.  I had planned on testing it with only the center magnet first, then adding the peripheral magnets to see what the difference is.  If it acts like my small prototype then adding the peripheral magnets will double the voltage.

I ordered the gears and associated parts today, and it will take a few days for them to get here.  So, in the meantime, I will finish off the small things that still need to be done, and probably spin it up to get some idea of what the output will be like. 

Offline shylo

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Re: Dia. Mag. Alternator
« Reply #92 on: November 04, 2010, 10:41:11 PM »
Hey Z so where the bearings insert ,..they're not tapered fit , so as compressed they tighten?.......you could try wrapping the outer dia. of the bearing with cellophane,...one layer at a time ...cone shaped ...so as it goes in gets tighter and tighter.....then just remove excess .....your bearing plates should keep it tight .....after awhile though due to friction the cellophane will break down.....maybe not worth trying ,but just trying to help.....it's up to you.......shylo

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #93 on: November 04, 2010, 11:28:25 PM »
Its a sealed, press fit bearing...

http://www.grainger.com/Grainger/wwg/search.shtml?searchQuery=1ZGE6&op=search&Ntt=1ZGE6&N=0&sst=subset

You're suggesting that I fix it with tape?  Please...

This is industrial quality...

I fix it with my Blacksmithing skills...

Offline shylo

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Re: Dia. Mag. Alternator
« Reply #94 on: November 05, 2010, 01:36:28 AM »
Z not trying to be discouraging but,...using a hammer and a punch to get rid of the 2mil slack in the bearing seat is not going to work ...............it will never be centered let alone balanced.......with the cellophane ....if its not perfect ..easy to go back and try again.....once you punch it ...that dimples' there to stay..........shylo

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #95 on: November 05, 2010, 01:49:30 AM »
LOL!  Finesse, duh, U underestimate my skills...

Offline tbird

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Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #97 on: November 06, 2010, 05:42:51 PM »
OK, I took a 5/16 inch flat faced punch worked around the periphery of the hole.  Put the punch down, tap tap.  Move it around maybe 15 degrees and tap tap.  Work all the way around the hole once, then fit the bearing.  Still loose, going around again.  Put the tap down, tap tap.  Move it 15 degrees and tap tap.  I had to go around the circle three times.  Always use uniform strikes with even pressure and don't get in a hurry...

So, that's how you reduce the size of a hole in sheet metal.  There are limits to this.  I only had to move this hole 1 mils on each size.  The further you have to move it the thinner the metal gets, so its not gonna work with a larger error...

You can kinda see the strike marks in this picture...

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #98 on: November 06, 2010, 06:17:06 PM »
I decided to use the Anvil instead of the machine vise.  The Anvil doesn't move as much.  This plate only needed one revolution of strikes, and was perfect.  Its press fit, like it should be, no lash...

Between the Hammer and the Anvil...
http://www.youtube.com/watch?v=PwcS5e0OYQM

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #99 on: November 06, 2010, 08:45:23 PM »
OK, now I have the bearing refit done.  That only took about 4 hours.  I rearranged the pieces that were spacing the bearing plates from the core.  I calculated the length of the shaft mounting collars, and the seat of the bearing plate mounts, and the shaft is shorter by 10 mils (calculated).  So that's 5 mils on each end of the shaft.  Then the bearing plates bow inward slightly from the blacksmithing process.  When it is bolted together there is no detectable play in any direction.

Now, we are ready to spin...
« Last Edit: November 06, 2010, 09:35:15 PM by z.monkey »

Offline nievesoliveras

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Re: Dia. Mag. Alternator
« Reply #100 on: November 07, 2010, 01:44:11 AM »
Hope for the best!

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #101 on: November 07, 2010, 02:23:07 PM »
Gave it a spin this morning...

Keep in mind here that the peripheral magnets are not spinning, and their strong magnetic fields are possibly interfering with the center magnet that is spinning.  Also, I am spinning it with a battery powered drill which has a maximum RPMs of 1400, and that equates to 23 Hertz.  So we are not spinning it nearly as hard or fast as it potentially could be spun.  Remember that it should be able to spin up to 24000 RPM, or 400 Hertz.

Open circuit voltage is around 14.5 VAC.  I used a 68 Ohm power resistor for a load.  Under load the voltage dropped to 4.1 VAC, and with a 65 Ohm (measured) load that is 63 milliAmps.  So that's a little more than a quarter watt.  I expect this thing to do much better when I get the peripheral magnets spinning.  Waiting for the timing gears now.  They may be here in a couple of days...

Offline nievesoliveras

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Re: Dia. Mag. Alternator
« Reply #102 on: November 07, 2010, 03:39:10 PM »
At least it is working!

Offline z.monkey

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Re: Dia. Mag. Alternator
« Reply #103 on: November 07, 2010, 11:42:43 PM »
At least it is working!
Thanks Jesus,

Here is a little video I made of it spinning at a very slow speed.  I put a compass on the mounting plate so you can see the magnetic  field spinning.  It is turning at maybe 1 or 2 Hertz, and it is still producing 1.5 VAC.  I am feeling good about this.  Once the peripheral magnet timing is worked out, then this little alternator is gonna rock...

http://www.youtube.com/watch?v=q1LD9X1QxMo

Offline nievesoliveras

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Re: Dia. Mag. Alternator
« Reply #104 on: November 08, 2010, 12:13:31 AM »
Again. you deserve to have a successful generator!

Jesus