Author Topic: A generator for Elmer. (Read 27632 times)

modeldozer · « **on:** December 13, 2015, 03:08:39 PM »

I wanted to model something to do for my Elmer mill engine so came up with this generator based on the fields and armature from a vacuum cleaner.

The various parts will be machined from solids.

This piece will become the main housing.

A template was printed and glued to the piece. It was set up on the mill and cut with a slitting saw to mark where to cut off some of the excess.

The centre of the main bore was located and drilled 12mm for location on the rotary table.

The excess was cut of with a hacksaw.

The First side was milled.

The centre was milled out halfway.

Then it was flipped over and relocated.

The second side was milled.

The centre was milled out.

The housing was set up directly on the mill table and the centre located.

It was bored to final dimension.

Then it was set up in the vice with the mounting surfaces level.

The surfaces were milled to dimension and holes drilled and tapped to mount the “feet”.

It was flipped and the holes for two eyebolts spot faced, drilled and taped.

All done and with the field fitted.

Cheers
Abraham

RobWilson · « **Reply #1 on:** December 13, 2015, 03:20:58 PM »

Very nicely done Abraham

Rob

awemawson · « **Reply #2 on:** December 13, 2015, 03:25:09 PM »

A lot of work there Abraham, well done it looks the business

ieezitin · « **Reply #3 on:** December 14, 2015, 06:54:03 PM »

A lot of work to whittle down to a housing.... nice work .. great result for a worthy cause..

Anthony.

Noitoen · « **Reply #4 on:** December 15, 2015, 03:06:21 AM »

Nice job but, to work properly, the field coils will have to be rewound with much more windings of thin gauge wire.

RotarySMP · « **Reply #5 on:** December 15, 2015, 03:19:04 AM »

Really nice Job, but you really need to set up for casting.
Mark

modeldozer · « **Reply #6 on:** December 15, 2015, 09:13:45 AM »

Thank you all for the kind words.
Unfortunatly I do not have space for a casting setup.
I quite like unveiling the hidden parts within.

Cheers.
Abraham

joshagrady · « **Reply #7 on:** December 15, 2015, 12:52:17 PM »

Abraham,
As always, it's looking good.
I seem to remember that I know a guy who worked in a rewinding shop in Alcoy (that's right around the corner from you, right?) Would you like me to try and track him down?

modeldozer · « **Reply #8 on:** December 15, 2015, 04:48:22 PM »

Hi Joshagrady,

Thank you for the offer but for the moment I have other plans for the fields.+

Abraham

SteveT · « **Reply #9 on:** December 15, 2015, 04:54:21 PM »

Abraham my complements on a well made project :-)

DavidA · « **Reply #10 on:** December 16, 2015, 04:50:58 AM »

Abraham,

Great project.

When it's finished you will not have to worry about power cuts.

Dave.

bertie_bassett · « **Reply #11 on:** December 16, 2015, 12:16:45 PM »

Looking great ! Always amazing what you can find hidden away inside a lump of metal.

modeldozer · « **Reply #12 on:** December 20, 2015, 06:48:23 AM »

Hi all,

Thanks for the kind comments.

For the housing “feet” a couple of pieces of 6mm aluminium plate were milled square and to size

Holes were drilled and countersunk.

Some corners were rounded over.

The finished feet.

And mounted on the housing.

A couple of bosses were turned for the eyebolt locations.

For the rear bearing block a piece of aluminium was milled square and to size, the centre for the bearing was located and spot drilled.

Material was milled away to start forming the boss of the bearing block and the bearing hole was drilled.

The boss and the hole were finished with the boring head.

The part was flipped over and the process repeated.

Here the boring bar can be seen mounted “wrong way around” to cut the outsides of the bosses, the mill was run in reverse for this.

Cheers
Abraham

John Rudd · « **Reply #13 on:** December 20, 2015, 07:30:45 AM »

Nice work there Abraham

As this is vac motor, I presume its series wound? You have access to the ends of the field coils, how are you going to excite them, seperate regulator?

Alan Haisley · « **Reply #14 on:** December 20, 2015, 12:10:57 PM »

Lovely work. Are the bosses glued in or will the ringbolts hold them in place?

modeldozer · « **Reply #15 on:** December 20, 2015, 01:40:16 PM »

John.
Yes it was series connected and the connections are availible, will add some small magnets to start the exitition and hopefully get away with a resistor to limit the field current. Need to get it build first for some experiments.

Alan,
Yes the bosses will be glued in.

Cheers
Abraham

modeldozer · « **Reply #16 on:** December 27, 2015, 07:13:46 PM »

Hi all,

The process was repeated for the front bearing block.

Then, starting with the rear bearing, the sides were milled.

Then mounted upside down and the centre located.

Mounting holes were drilled and the sides milled to size.

Then flipped over and the top milled and holes drilled. The top will be finished on the rotab later.

Milling the sides of the front bearing.

Drilling the mounting holes.

Cheers.
Abraham

krv3000 · « **Reply #17 on:** December 29, 2015, 06:25:41 PM »

in a word brill

modeldozer · « **Reply #18 on:** January 03, 2016, 11:35:02 AM »

A happy and prosperous 2016 to all.

Hi KRV300,
Thank you for the kind words.

The rear bearing post was set up in a chuck on the rotary table and the top finished.

The front bearing post was mounted on a centering arbor and finished.

The rear one was then mounted through the brush holder “ears” and rounded.

Made a small booboo on the rear post, turned the rotary table the wrong way.

The area was milled out square and a insert made to be glued in place.

Both posts so far.

Cheers
Abraham

joshagrady · « **Reply #19 on:** January 04, 2016, 08:34:21 AM »

Mistakes are inevitable in this life. The important thing is knowing how to fix them. Keep going with your wonderful work.

Happy new year.

awemawson · « **Reply #20 on:** January 04, 2016, 09:09:16 AM »

A good sound re-work that Abraham - and the through bolts will keep it secure

modeldozer · « **Reply #21 on:** January 06, 2016, 06:08:00 PM »

Hi Josha and Andrew,

Thank you for the kind comments.

For the base a template was printed to drill some mounting holes.

It was mounted on some packing pieces and the outside milled square and to size.

The cutout for the housing to sit in was gang drilled and removed.

It was then milled to size.

The top was milled away to form the four mounting pads.

A step was milled around the outside edge.

The corners of the step and at the bottom of the pads were filleted with a ball nose and round over end mills.

Cheers
Abraham

Alan Haisley · « **Reply #22 on:** January 06, 2016, 11:37:50 PM »

I'm really enjoying this build.

steampunkpete · « **Reply #23 on:** January 07, 2016, 10:22:44 AM »

Fabulous. I wish that I was this good. I'm looking forward to seeing the end result.

modeldozer · « **Reply #24 on:** January 10, 2016, 09:33:36 AM »

Hi Alan and steampunkpete,

Thank you for the kind comments.

The corners of the base were rounded with the various cutters using step off charts created in a spreadsheet.

The tops of the pads were given a quick skim with a face mill.

All the holes were located, drilled and tapped.

I used a clamp on the one side as a reference so the part can be flipped.

Four mounting holes were then drilled in the bottom of the base.

The base with all the major machining done.

And a few group shots.

Then it was on to making studs. I used treaded bar for the 16 M3 ones and cut off screws for the 8 M2 ones. Only one picture of facing them to length.

The four insulators were turned from PVC.

Put the vice back on the mill and dialed it in.

I did not have any square brass stock so a few slices were cut from some flat and milled square.

The brush holder stand offs were then turned from these.

Then flipped around and parted off and faced to correct length.

The stand off parts so far.

A couple of washers were also turned.

More to follow.

Cheers.
Abraham

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Author Topic: A generator for Elmer. (Read 27632 times)

RobWilson