Vintage generator based on ceiling fan

[Daniel Williams]

The wheel of a hover board might be even better as it already contains the magnets.

For the price of the magnets I now need for the ceiling fan, one can also buy a 2nd had or broken hover board.

Well, when I went down the ceiling fan route, I know that a Bruce Macbeth was already turning one successfully. Plus, I had several old fans at my disposal. By putting my own magnets in, if I found too much load, I could change out for smaller magnets.

As a response to K2, I purposely keep as much theoretical tech out of my hobby ever since I left all that at the office. The magnetic cogging isn't much. However as the load increases, the the torque demand increases. That is the largest factor. I just won't overload my engine, that's all.

Dan

 

[xander janssen]

Obsolete coils removed and wires replace to reduce the imbalance and stripped an old servo motor to serve as a faux (imitation) exciter.

 

[xander janssen]

Added insulated slip rings. Next will be the stator.

 

[Steamchick]

Fair comment Dan. Well less than 20% of my career was doing the sums... Most was trying to pursuade people to follow the rules and Regulations as "they" (usually middle management) would be the ones in court if they ignored the Regs. And results of calculated designs and tests.... Top management were very good and listened to proper Engineering advice. But that's another tale.
Recently, I have corrected 2 boiler designs, done 2 burner designs, and fixed them close to calculated designs because they were simply wrong and didn't work.
Not knowing the right fix, I find the numbers a good guide, if not perfect. With 3 or more variables, the sums and results save me chasing the wrong thing to make things work.
But I also simply use "experience" where I think that is OK, and sometimes that works. For me.
Enjoy the hobby. A fascinating thread!
K2

 

[Daniel Williams]

Yep, your slip ring looks just like mine, I just used some black delrin because it was there. I threaded the inside and screwed it onto the shaft. Only problem is, to remove it I have to unsolder the wires.
Steamchick - I say that I wanted to leave the technical electrical stuff at my old office, but I've spent the better of 2 months making an automatic coil winder for a new project. Not only did I have to dig back into the transformer world, I had to finally figure out some Fusion 360 basics for 3D printing, and finally learn some C for an Arduino controller.
Makes my brain hurt sometimes.

Dan

 

[xander janssen]

1st test with the generator running at 330 rpm in the lathe. Only one of the 16 magnets in place and still without back iron to direct the magnetic flux.

 

[Steamchick]

A big WELL DONE! Dan. I had half a dozen or more CAD training courses at work... used it to read drawings, sectioning, etc. but not drawing. That was a job until mid 1980s, now a hobby using the old pencil, set-squares, brain, slide rule, etc.
Now retired I just don't want the brain buster called CAD. Going back to basics and learning a whole new system every 2 or 3 years was just extra work to do the same old job for me.
If I make a one off, I want to use my skills designing it and making it accordingly. If I need mass production, I'll learn the tools (CAD etc.) and make the jigs, fixtures, etc. to do that - but that was the job, not a hobby for me.
Computer modelling of a multiple mass & spring system driven by an air motor to accelerate and decelerate the system was a good job for a computer... Or using it to create operation and maintenance manuals for a power station... But modern use as a clever telephone/messenger simply turns me off. As does CAD in many cases. For the one-offs I do the pencil is quicker, or slide-rule, calculator, etc. but for repetitive calculations I simply write the calculations into a spreadsheet - then repeat many times.
In the workshop (all 2 sq.m) I often use chalk on a board to work-out dimensions, etc. - Who needs a pen and paper? - That's high tech from Egyptian times! Stone masons were scratching on rock for millennia before quill, ink and paper were developed.
And CAM in the hobby shop? Nowt wrong with a good hand, hacksaw and file if you ask me... - More fun too! And such pride when it is right and finished. After all. Most of the old mechanical artefacts we admire were made that way.
K2