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Author Topic: A generator for Elmer.  (Read 40397 times)

Offline modeldozer

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A generator for Elmer.
« 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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/GeneratorLayoutV14SEfull2.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/GeneratorLayoutV14NEfull2.jpgA generator for Elmer.

The various parts will be machined from solids.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00001.jpgA generator for Elmer.

This piece will become the main housing.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00002.jpgA generator for Elmer.

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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00003.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00004.jpgA generator for Elmer.

The excess was cut of with a hacksaw.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00005.jpgA generator for Elmer.

The First side was milled.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00006.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00007.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00008.jpgA generator for Elmer.

The centre was milled out halfway.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00009.jpgA generator for Elmer.

Then it was flipped over and relocated.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00010.jpgA generator for Elmer.

The second side was milled.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00011.jpgA generator for Elmer.

The centre was milled out.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00012.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00013.jpgA generator for Elmer.

It was bored to final dimension.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00014.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00015.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00016.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00017.jpgA generator for Elmer.

All done and with the field fitted.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00018.jpgA generator for Elmer.

Cheers
Abraham

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RobWilson

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Re: A generator for Elmer.
« Reply #1 on: December 13, 2015, 03:20:58 PM »
 :clap: :clap: :clap: :clap: Very nicely done Abraham    :thumbup:



Rob
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Offline awemawson

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Re: A generator for Elmer.
« Reply #2 on: December 13, 2015, 03:25:09 PM »
A lot of work there Abraham, well done it looks the business  :thumbup:
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Andrew Mawson
East Sussex

Offline ieezitin

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Re: A generator for Elmer.
« 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.
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Offline Noitoen

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Re: A generator for Elmer.
« 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.
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Offline RotarySMP

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Re: A generator for Elmer.
« Reply #5 on: December 15, 2015, 03:19:04 AM »
Really nice Job, but you really need to set up for casting.
Mark
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Best regards, Meilleures salutations, Mit freundlichen Grüßen, Cu salutari
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Offline modeldozer

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Re: A generator for Elmer.
« 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
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Offline joshagrady

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Re: A generator for Elmer.
« 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?
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Offline modeldozer

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Re: A generator for Elmer.
« 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
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Offline SteveT

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Re: A generator for Elmer.
« Reply #9 on: December 15, 2015, 04:54:21 PM »
Abraham my complements on a well made project :-)
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Offline DavidA

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Re: A generator for Elmer.
« 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.
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Offline bertie_bassett

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Re: A generator for Elmer.
« 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.
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Offline modeldozer

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Re: A generator for Elmer.
« 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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00019.jpgA generator for Elmer.

Holes were drilled and countersunk.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00020.jpgA generator for Elmer.

Some corners were rounded over.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00021.jpgA generator for Elmer.

The finished feet.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00022.jpgA generator for Elmer.

And mounted on the housing.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00023.jpgA generator for Elmer.

A couple of bosses were turned for the eyebolt locations.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00024.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00025.jpgA generator for Elmer.

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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00026.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00027.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00028.jpgA generator for Elmer.

The part was flipped over and the process repeated.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00029.jpgA generator for Elmer.

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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00030.jpgA generator for Elmer.

Cheers
Abraham
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Offline John Rudd

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Re: A generator for Elmer.
« Reply #13 on: December 20, 2015, 07:30:45 AM »
Nice work there Abraham :bow:

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?
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Offline Alan Haisley

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Re: A generator for Elmer.
« 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?
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Offline modeldozer

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Re: A generator for Elmer.
« 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
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Offline modeldozer

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Re: A generator for Elmer.
« Reply #16 on: December 27, 2015, 07:13:46 PM »
Hi all,

The process was repeated for the front bearing block.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00031.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00033.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00034.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00035.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00036.jpgA generator for Elmer.

Then mounted upside down and the centre located.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00037.jpgA generator for Elmer.

Mounting holes were drilled and the sides milled to size.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00038.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00039.jpgA generator for Elmer.

Milling the sides of the front bearing.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00040.jpgA generator for Elmer.

Drilling the mounting holes.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00041.jpgA generator for Elmer.

Cheers.
Abraham



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Offline krv3000

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Re: A generator for Elmer.
« Reply #17 on: December 29, 2015, 06:25:41 PM »
in a word brill
 :drool:
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Offline modeldozer

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Re: A generator for Elmer.
« 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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00042.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00043.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00044.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00045.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00046.jpgA generator for Elmer.

Both posts so far.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00047.jpgA generator for Elmer.

Cheers
Abraham
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Offline joshagrady

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Re: A generator for Elmer.
« 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.
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Offline awemawson

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Re: A generator for Elmer.
« 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  :thumbup:
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Andrew Mawson
East Sussex

Offline modeldozer

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Re: A generator for Elmer.
« 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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00048.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00049.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00050.jpgA generator for Elmer.

It was then milled to size.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00051.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00052.jpgA generator for Elmer.

A step was milled around the outside edge.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00053.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00054.jpgA generator for Elmer.

Cheers
Abraham
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Offline Alan Haisley

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Re: A generator for Elmer.
« Reply #22 on: January 06, 2016, 11:37:50 PM »
I'm really enjoying this build.  :D
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Offline steampunkpete

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Re: A generator for Elmer.
« 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. :bugeye:
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Offline modeldozer

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Re: A generator for Elmer.
« 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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00055.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00056.jpgA generator for Elmer.

All the holes were located, drilled and tapped.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00057.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00058.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00059.jpgA generator for Elmer.

The base with all the major machining done.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00060.jpgA generator for Elmer.

And a few group shots.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00061.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00062.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00063.jpgA generator for Elmer.

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.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00064.jpgA generator for Elmer.

The four insulators were turned from PVC.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00065.jpgA generator for Elmer.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00066.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00067.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00068.jpgA generator for Elmer.

The brush holder stand offs were then turned from these.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00069.jpgA generator for Elmer.

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

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00070.jpgA generator for Elmer.

The stand off parts so far.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00071.jpgA generator for Elmer.

A couple of washers were also turned.

http://i519.photobucket.com/albums/u356/dozerd10/Workshop/Projects/Generator/Image00072.jpgA generator for Elmer.

More to follow.

Cheers.
Abraham

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