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Pulse Motor Version 1.0

I have started work on my Pulse motor and Opted for using Aluminium rather than PlexiGlass.

Managed to get hold of a nice 200MM Aluminium Bar offcut.

First I decided to let the CNC Router Mark it up from dead center as this will give me the guidelines also for the magnets.

Next Popped a 20mm hole in the center and lathed out some couplers out of 32mm Aluminium Bar.

The uprights needed a 25mm hole cut in the side to allow the axle to slide through to the bearings, again opted for the CNC Router as more accurate.

Attached the bearings using 10mm T Nuts.

After tapping the uprights I attached them to a 25mm Aluminium base using M12 Bolts.

Then I slide the bar through and aligned all the bits.

Next I needed a timing disk, so again set the CNC Router going.

Censor Wheel fitted and a Ruler so you can get an idea of the height.
The two Plexiglass poles will hold the Opto Sensors and the wheel will sort out the trigger timing..

Below the 20mm Magnets that will be fitted flush into the wheel and one of the Electro Magnets I will be using.

31/03/2007 Managed to get in the workshop this afternoon and started to fit the Pulse Motor with the magnets and generator.


Above showing the first magnet nice and flush with the Wheel and held in place by a brass bolt.
Must admit was a tough one to Drill to 20mm as there was not enough room under my Drill stand once the long Blacksmith Drill had gone in the chuck, so did it by hand in the end.


I mounted one of the EM's on some small aluminium angle and insulated it with nylon washers. My calculations came out good leaving about 1-2mm gap between the EM and wheel.
I grabbed a Drill Battery I have here which is a bit too high Voltage really (24 Volts) and pulsed the EM quickly to see what would happen. Yep sure enough the magnet shot away from EM pretty damm quick and produced a full revolution easy enough.
Little bit worrying about the Sparks coming out as using my hands to short the wires against the battery was not exactly accurate Micro Second timing LOL. These EM's do pull a whack of current, but will know more when the circuit is in place.


Next I started work on mounting a generator from a Wind Turbine.
It is wired as three phase and each phase is rated at 48 Volts, 4 Amps so be interested when in place to see what drag it creates when the wheel is spinning and what RPM is needed for optimun output.


Here you can see the coil with the Rotor removed. Nice that the middle hole of the Rotor is exactly 20MM a matches my bar and the only thing left to do is cut a slice in the bar to take the woodruff key.
The Rotor has four beefy magnets on it that glide about 1mm close to the pickup coils.
The alignment is gonna have to be spot on GULP, but atleast the 20mm bar is straight and using the tough bearings do not give any play at all, so a good start.


Would love too carry on and get this thing finished this weekend, but it seems that is about my lot for this weekend as got to do some other stuff tomorrow grrrrrrrrrr, but will see how it goes.

I have got a 12V 15AH sealed battery on the way with charger to power the circuit now which should also supply enough current for the EM's. This should allow me to experiment and get things running smooth, then I will start looking for banks of capacitors to replace the battery.

I am going to start off with one EM and one Magnet mounted in the wheel and increase it as needed, again just experimenting until I find what works the best.

 

Last Updated 01/04/2005

PLEASE NOTE.

Sorry I am not posting the results of my experiments as this would take too much time.
But when I have something I can shout about and that works 100%, then be assured I will post an update.
For now this is just a Blog as such of what I am working on.