Model generator build from casting kit.

Help Support HMEM:

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
171
Reaction score
201
Hi all, not sure if this is in the correct forum here as its not an engine but it is made from castings and it realy only works when coupled with an engine.
Im sure some of you will find it interesting enougth to follow along anyway.
I have had some questions regarding the making of this model so il record a full build log with plenty of photos to show you how i make this model.
I have already recorded the design process of the model in the 'work in progress' thread if you are interested in that.
This log will just be a record of the build and machining steps i use to finish the model.

This is how the finished model looks..
20210614_135058.jpg

20210614_135036.jpg


The generator is designed for lower speeds around 500 RPM this is relativly slow when compared to the the available DC dynamo model kits available that require 4000+ rpm.

This is how the kit of parts looks it includes all castings, barstock, fittings, wireing, drawings, pre made coils and a plastic 3d printed stator ring.
20210820_152444.jpg

I start with the base casting first this just requires the mounting points milling level.
20210922_140417.jpg

A simple clamp setup is used to hold the part on the milling machine. Forst i machined the bearing mount points then rearange the clamp and lower the spindle 20mm to cut the lower stator mounting points.
20210922_142810.jpg

Thats all for today i will get stuck into this tomorrow and record the progess.

Best regards.

Luke.
 

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
171
Reaction score
201
Hi all.
Today i machined the stator housing.
20210923_120712.jpg

First i centered the casting in the 5" 4 jaw chuck then bored out the center to 86mm.
20210923_123542.jpg

Check the fit with the stator ring before removing from chuck. It should be a nice push fit.
20210923_123618.jpg


Next i machine the stator housing feet level. I clamp the part to a 90° angle plate and use a height gauge to mark the cut lines then transfer it to the milling machine vice to mill the feet.
20210923_141250.jpg

Then marked out the feet screw holes and drilled through 3.2mm.
20210923_144541.jpg
20210923_152014.jpg

The last step is drilling the top bosses for the lifting eye points. Drilled through 2.4mm and tap m3.
20210923_153430.jpg

And the finished stator housing with the base plate after some deburing and a little fettle. Il use the stator to mark the fixing screw holes through.
20210923_153834.jpg

More coming soon.
 

Attachments

Last edited:

Latest posts

Top