Model generator build from casting kit.

Help Support HMEM:

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
193
Reaction score
258
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
193
Reaction score
258
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:

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
193
Reaction score
258
Hey all, sorry its been a while.
Il try and get the generators finished this week but heres a little update so far.
The bearing housings were machined today..
20211013_133300.jpg

First milled the bottom flat..
20211013_135034.jpg

Then bore 15mm for the bearing fit.
20211026_125100.jpg

Then drill the fixing holes.
20211026_143602.jpg

And the finished bearing housing..
20211026_144335.jpg

More to come very soon.
 

olympic

Well-Known Member
Joined
Feb 14, 2011
Messages
150
Reaction score
62
Location
Ontario, Canada
Keep this up!

For a non-technical guy like me who is trying to make a Breisch Associated engine from castings, your setups and procedures are very informative.
Yesterday I spent the entire afternoon puzzling over how to clamp the base casting to the mill table, and finally came up with the bar arrangement you used in your post, and if I had seen your post first I'd have had the answer in seconds.

If you keep teaching I may just keep learning.
 

DLM

Project of the Month Winner!!!
Project of the Month Winner
Joined
Nov 7, 2010
Messages
62
Reaction score
27
Hey all, sorry its been a while.
Il try and get the generators finished this week but heres a little update so far.
The bearing housings were machined today..
View attachment 130319
First milled the bottom flat..
View attachment 130320
Then bore 15mm for the bearing fit.
View attachment 130321
Then drill the fixing holes.
View attachment 130322
And the finished bearing housing..
View attachment 130323
More to come very soon.
Hi I am building the same generator and will be following along Don
 

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
193
Reaction score
258
Today i assembled the stator rings.
The stator ring is plastic 3d printed.
The 12 coils are premade and set with epoxy resin with 150 turns of megnetic wire.
20211027_123811.jpg

20211027_135253.jpg


This is the back side of the coil with the start end end marked.. the start of the coil can easily be determined as the wire goes to the center bobbin. This side should be glued to the stator ring.
20211027_140403.jpg

20211027_140352.jpg

20211027_140537.jpg



The stator ring with all the coils fixed in the same orientation and the wires are trimmed to about 30mm long.
20211027_153538.jpg

Use a flame to burn off about 10mm of the enamal coating on all the wires.
20211027_153642.jpg

Use a fine sand paper to clean the wire to bare copper..
20211027_154339.jpg

I will try to explain the wirering as best i can, the coils must be alternating in the direction of winding.
All the coil starts are now on the left of each coil marked with an 'L' i start by joining the left wire of coil 1 to the left wire of coil 2..
20211027_155338.jpg

The right wire of coil 2 is the connected to the right wire of coil 3. Then the left wire of coil 3 is connected to the left wire of coil 4 and the pattern repaets untill there are two end wires..
20211027_155458.jpg

.
.
Next page..
 

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
193
Reaction score
258
Twist all the joints together and solder. Make sure you removed all the wire enamal and no oily fingers for the solder to wet. Then cut short pieces of the shrink tube and fit over the conections..
20211027_162536.jpg

Shrink with a small flame.
20211027_162831.jpg

Then took the joints neatly in between the coils..
20211027_162936.jpg

And finaly solder the last two ends onto the extension wires and the stator is complete..
20211027_163904.jpg

More to come soon.

Regards.

Luke.
 

SirJohn

Active Member
Joined
Feb 4, 2011
Messages
27
Reaction score
5
Where did you purchase this kit? Sorry if you mentioned the source in your in your write up but I missed it if you did.
 

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
193
Reaction score
258
Hi all, sorry for the slow progress on this build ive just been keeping up with orders for the kits amongs everything breaking down this last weeks.
I just received my order of 200 magnets so that should keep me going for a while and i can finaly finish this build log.
Todays work as follows.
The pulley casting and bar stock for the shaft.
20211103_135659.jpg

The shaft is just trimmed to length.
The pully casting was first chucked using the larger spigot side. the small center was then turned tru and the pulley faced off.
20211103_144054.jpg

Then chucked on the smaller spigot and faced off the next side, trimmed the diameter and cut a v groove on the pulley.
20211103_144858.jpg

It was then re chucked on the larger spigot then the smaller spigot trimmed off and the center hole drilled 6mm.
Next step was center punch and drill and tap for the grub srew.
20211103_151127.jpg

20211103_151830.jpg

Next part the shaft spacer. Made from the 10mm brass bar and simply drilled 6mm and parted to length.
20211103_153812.jpg

20211103_154134.jpg


Next onto the rotor casting.
20211103_154604.jpg

First chucked on the inner rim and cut the outer diameter to 72mm, faced off and drilled 6mm through.
20211103_160206.jpg

Then re chucked on the outer diameter and the other side faced off.
20211103_164053.jpg
 

darwenguy

Well-Known Member
Joined
Oct 26, 2013
Messages
193
Reaction score
258
The turning work now done on the rotor.
20211103_164451.jpg

And test fit to make sure of clearance in the stator ring.
I like to make the parts in this order to Make sure everything lines up before fixing anything to the base.
20211103_164809.jpg

20211103_164819.jpg

More soon.
 

Latest posts

Top