Wednesday 16 October 2013

Generator Update

The new drive plate has been made and fitted.

Once the drive plate and new support frame was fully bolted into place a final dial gauge test was done. On the end of the shaft there was 5/1000th of an inch runout. This shaft will be cut back on final assembly to about 11/4" (30mm) when the HRC90 coupling is fitted. This will reduce the runout even more. The coupling is designed to take way more runout than this.

This video explains better than I ever could how the taper lock system works.

Saturday 5 October 2013

New Genset Frame

This is the new frame I have made to do 2 jobs. 1st job is to support the rear of the engine. Previously the 230v alternator body did this. The new 12v alternator isn't designed to do this

This doesn't look much but it took several hours of head scratching and trying different things. There was 2 main problems / considerations in the design. The 1st and most important was the maintain all the original parts so it could be put back to original. 2nd, I wanted it all to fit back in the original sound reducing box.  The other minor problems were to ensure access and use all the original bolts and the exhaust pipe route got in the way. The final consideration was to ensure the new alternator could be fitted and removed as the pad mount lugs are wider than the diameter.

The pads of the alternator will sit flat on spacers on top of the flats of the bottom angle irons and bolted through 

Friday 4 October 2013

HP Calculations

In reply to a comment here, I realised I hadn't shown my workings!

So is the 12hp engine powerful enough?

This would be the maximum output.  It's very unlikely my batteries could ever draw this much. The plan is to run the engine at 1500rpm, however it can be run faster if needed.  Why 1500?  well its very quiet at that rpm, but even at 2000rpm its a fraction of the noise at 3000rpm.

This is the horsepower required to achieve this.

This is what I am looking to achieve at 1500rpm

This is the horsepower required.

These calculations are of course in ideal situations with a new engine, however there is still about 33% to play with.

So time will tell, but I'm confident the engine will drive it.  Interestingly when I was considering a 1500rpm 4 pole 230v alternator it was calculated by the intended supplier that it could not exceed 3kw output.

Wednesday 2 October 2013

US Alternator Has Arrived

The Ecoair alternator arrived today from America :-)

Just a picture quick entry this time.

Its big! and it's heavy 18kg!

In the interim I have been looking at drive options.  I have decided to make a new drive plate:-

Old drive plate

to which I will probably use a Fenner HRC Coupling or possibly a Fenner Tyre Coupling.