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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
Make your own Generator
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<blockquote data-quote="JustPlainBill0" data-source="post: 108703" data-attributes="member: 4182"><p>There are gusseted L brackets available, but in general I agree they aren't so good for this purpose. This mount (next to the Vincent cradle):</p><p></p><p>[ATTACH=full]28273[/ATTACH]</p><p></p><p>is for a 52mm spindle motor . That style is available in 57mm and other sizes, but the mounts tend to get wider as the bore diameter increases, so attachment to the engine case gets more difficult since you have to offset the mount (rearward) to center the motor in the engine case opening and you run out of room on the top of the case for the mount.</p><p></p><p>I'm acquiring a nice motor collection too Vic. While I was awaiting an answer regarding bearings used on the 60 mm China motor, I ordered a 100x52 mm 50 watt 24VDC brush motor that I will try with the spindle motor mount above. You can see I'm moving away from high output generators. My experience with the 12K rpm 200 watt motor at high RPM was not good. At 60 psi to the die grinder, and a 55 watt bulb, I recorded 60+ volts (upper limit of my meter) before the meter died and fried a couple of 12V sealed beam headlights along the way. My earlier test at 60 psi showed 18 volts with a 55 watt load.</p><p></p><p>Two things I learned using the air die grinder to test the generator: First you need to be pretty damn sure you know the relationship between air pressure to the die grinder and voltage output by the generator before seriously testing. I've been using a linear model: for example, if the motor needs 12VDC to spin 3000 RPM, I calculate that each additional volt will turn the motor an additional 250 rpm. And that when the motor is used as a generator, each additional 250 RPM will generate one more volt when turning the generator with a drill or die grinder. So to estimate generator speed, I measure the voltage produced by the air die grinder at a set air pressure and calculate motor speed by multiplying voltage times 250 for my estimate. That process can be repeated at different air pressure levels to the die grinder and you can determine approximate power output at different RPM and then at different road speeds. The purpose of this is not only academic, but it allows you to limit generator speed to real world levels during testing so you don't blow out your test equipment. Crude, but as a friend said "it's good enough for who it's for".</p><p></p><p>This leads to the second thing I learned: New carbon motor brushes for inexpensive China motors are made with barely concave surfaces that need to be "seated" to match the commutator shape before they deliver full power. Seating is done by running the motors with light or no load for a period of time?? to let them wear-in. If the brushes are not seated, power reading and generator performance will not be peak until they are. My failure to let the brushes seat probably accounts for the higher than expected power outputs that fried my test equipment. Lesson learned.</p></blockquote><p></p>
[QUOTE="JustPlainBill0, post: 108703, member: 4182"] There are gusseted L brackets available, but in general I agree they aren't so good for this purpose. This mount (next to the Vincent cradle): [ATTACH type="full"]28273[/ATTACH] is for a 52mm spindle motor . That style is available in 57mm and other sizes, but the mounts tend to get wider as the bore diameter increases, so attachment to the engine case gets more difficult since you have to offset the mount (rearward) to center the motor in the engine case opening and you run out of room on the top of the case for the mount. I'm acquiring a nice motor collection too Vic. While I was awaiting an answer regarding bearings used on the 60 mm China motor, I ordered a 100x52 mm 50 watt 24VDC brush motor that I will try with the spindle motor mount above. You can see I'm moving away from high output generators. My experience with the 12K rpm 200 watt motor at high RPM was not good. At 60 psi to the die grinder, and a 55 watt bulb, I recorded 60+ volts (upper limit of my meter) before the meter died and fried a couple of 12V sealed beam headlights along the way. My earlier test at 60 psi showed 18 volts with a 55 watt load. Two things I learned using the air die grinder to test the generator: First you need to be pretty damn sure you know the relationship between air pressure to the die grinder and voltage output by the generator before seriously testing. I've been using a linear model: for example, if the motor needs 12VDC to spin 3000 RPM, I calculate that each additional volt will turn the motor an additional 250 rpm. And that when the motor is used as a generator, each additional 250 RPM will generate one more volt when turning the generator with a drill or die grinder. So to estimate generator speed, I measure the voltage produced by the air die grinder at a set air pressure and calculate motor speed by multiplying voltage times 250 for my estimate. That process can be repeated at different air pressure levels to the die grinder and you can determine approximate power output at different RPM and then at different road speeds. The purpose of this is not only academic, but it allows you to limit generator speed to real world levels during testing so you don't blow out your test equipment. Crude, but as a friend said "it's good enough for who it's for". This leads to the second thing I learned: New carbon motor brushes for inexpensive China motors are made with barely concave surfaces that need to be "seated" to match the commutator shape before they deliver full power. Seating is done by running the motors with light or no load for a period of time?? to let them wear-in. If the brushes are not seated, power reading and generator performance will not be peak until they are. My failure to let the brushes seat probably accounts for the higher than expected power outputs that fried my test equipment. Lesson learned. [/QUOTE]
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Tech. Advice: Series 'B' / 'C' 500cc/1000cc Bikes
Make your own Generator
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