Author Topic: Bicycle Generator Project (Read 30359 times)

jaysicle · « **on:** May 13, 2011, 08:46:19 PM »

Hello,

Nice to think I may finally contribute something to this forum. If it is useful or entertaining to even one of us, I will be happy with that. Thanks to Norm and Ghurd for encouraging this... Some background and order of events.

In April 2006 I found this and other similar sites, and was immediately hooked.
My plan at the time was to build a small VAWT as a learning project. So I did.

I chose one of Hugh's PMA to start with - Dual rotor, 12 magnet, 9 coil, 3-phase
Magnets = 'Round' Neo-42's, 1" dia, 0.5" height
Coils = 20g, 100turns, one-in-hand
Rotor = 1/4" steel with hubs welded on to it, 1/2" shaft bore
Original Wiring = Star (I was happy just to see some Voltage at the start)

Here is the original machine...

Here is the current machine...

jaysicle · « **Reply #1 on:** May 13, 2011, 09:23:33 PM »

Still in the Spring of 2006, I had picked up (4) used 6V US Battery 2200's as a battery bank, but chickened out a bit even after building a case and venting to outside etc... (Hydrogen). Those batteries made their way to a golf cart supplier, and I did not work on any of this again until February of this year (2011). Not that you don't know what year it is, but just for record.

In January 2011, I decided to change a lot of things - mainly diet and excercise. I went from 225lb to 207.4lb current.
Mixed in with push ups, sit ups, Kempo, Winter walks, Kale, Spinach and Broccoli - was the bike.

I'd target 300 Calories and per day and go. Ended up 450 Calories, 50 minutes, 120bpm @30km/hr felt right.

There was some resistance involved to catch myself from powering too heavily and out of balance on each stroke - and during one of the rides, I put the two together. Excercise Bike using Wind Generator project parts. I figured that I was doing it anyway... so I started planning.

jaysicle · « **Reply #2 on:** May 13, 2011, 09:38:00 PM »

It was a bit awkward planning around workouts to modify the thing, but it had to be done. Well, that is what I told myself. Man, this is a powerful bug.

I had already built the generator and 3-phase AC to DC rectifier for the vawt project, so had that kicking around...

It was an old Vacuum Tube Voltmeter (hp) that I picked up.
It had a suitable overall size and internal aluminum frame for mounting heat sinks and bridge rectifiers, meters and such.

The front panel is just 0.10" aluminum sheet that I'd fit to the chassis...

Upper meter is A (0-10A), mid meter is VDC post bridge rectifiers (0-30VDC) and lower is VAC measured off of single phase (0-150VAC).

jaysicle · « **Reply #3 on:** May 13, 2011, 10:05:09 PM »

Photos of coil winding and generator assembly...

jaysicle · « **Reply #4 on:** May 13, 2011, 10:10:08 PM »

Battery Bank during hook up...

jaysicle · « **Reply #5 on:** May 13, 2011, 10:18:13 PM »

Current control panel...

Left Black = Inverter
Middle Metal Grey = Fused Disconnect (100A blade(+), 100A blade(-))
Smaller Metal Rightish Grey = 6V inter-connect Switch (fused soon)
Small(est) far Right Grey with green illuminated rocker = Solar Panel Disconnect / Battery feed

jaysicle · « **Reply #6 on:** May 13, 2011, 10:36:29 PM »

Missing in this so far is Ghurd's controller - which will alleviate the need for the small solar controller in the upper right corner of the control photo. Here is Ghurd's controller in current state, not complete... but a very fun start... I realize that this is not 'news', but he has designed and built a circuit (cost effective kit in fact) to provide a controlled dump of dangerous battery over-charge to a resistor bank, or an LVD low battery voltage load disconnect (your choice)...

jaysicle · « **Reply #7 on:** May 13, 2011, 10:52:50 PM »

Here is the most recent data that I have on the bike generator, which was just before I changed the driven sprocket from 14 to 19.
(It is now easier to pedal at moderate RPM) i.e.: I am currently at ~6-8A continuous at '27.5kph' cadence. Would really like 30kph, so 22 tooth driven... will have to fabricate that though - 22 tooth in #40 chain size at 1/2" bore is not common...

kph   Batt V    Current RPM   Power IRP    Possible Duration

0    12.79     0.00    0.00    0.00    0.00
14    13.00    0.71    350.00    9.19    All Day
16    13.00    1.41    395.00    18.38    All Day
18    13.20    2.83    440.00    37.33    All Day
20    13.20    5.30    485.00    69.99    20 min
22    13.20    8.48    530.00    111.99    1 min
24    13.20    12.73    575.00    167.98    20 seconds

jaysicle · « **Reply #8 on:** May 14, 2011, 12:05:45 AM »

Short term resultant use of energy produced is realistically 1:1 with this 48W device... (do you think it will rain?) $:-\$

In fact, most days as I ride I watch a show... sometimes I turn the TV off at commercials, sometimes I ride just to charge w/o TV.
The workout has become somewhat anaerobic now with increased resistance as RPM's increase. It is a lot like hockey actually.
I'll have to attempt to re-calculate actual calories burned with this increased / incremental resistance.
The bike reads 236 CAL. My soaked shirt reads 410 CAL.

jaysicle · « **Reply #9 on:** May 14, 2011, 12:54:02 AM »

As you can see, the batteries are AGM now.

There is also a solar component connected (reads 54W - have seen 39W), and the intent of the system is to be able use a dehumidifier during summer to help out the household air conditioner, and occasionally the 1/6 HP water pump for heat in the winter. Alternate and easier than the water pump (only because an extension cord gets power to it and I have already had it running) is the 75W blower on the wood fireplace insert.

I guess that is my first entry, open for comment / improvement.

Boss · « **Reply #10 on:** May 14, 2011, 08:07:21 AM »

Nice mod to the VAWT, your bike is really inspiring. That alternator is too sweet. How are people getting their coils so neat?

jaysicle · « **Reply #11 on:** May 14, 2011, 10:26:38 AM »

Thanks Boss, I appreciate it.

As far as coil neatness goes - here is a photo of the way that I wound mine.
Not to say that this is the 'best' way to do it... rather how I got there.

I used electrical tape around the perimeter when enough turns were reached, and after unscrewing the MDF coil former, used 3X tape around the legs. It was wound fairly tightly, but as you know... the copper pretty well forms out for you as you go. I have see nice flat wire ties used here as well, but you don't want any added thickness here really. Ideally, I think you'd want to be able to heat the coil in an oven while in the MDF / other former and let the jacket activate and adhere one winding to the next with no added gap thickness... but I haven't tried that yet.

Next photo is complete stator under 1/8" plexi sheet with the modification from Star to Independently Rectified Phases (IRP)...

willib · « **Reply #12 on:** May 14, 2011, 10:41:14 AM »

Very nice jaycicle,
Norm will like the excercise bike, and i do too.
that flywheel has some mass to it too.
The mass really helps when pedalling , dosn't it?
built this one several years ago

Great stuff !

jaysicle · « **Reply #13 on:** May 14, 2011, 10:42:18 AM »

Here is a chart showing measured stator temperatures. Mind you, this is not actual coil temperature, thermocouple was attached to outer plexi plate for readings. The magnets do create some good turbulence as they pass and help to cool it... In a way, I would like to see more efficiency, and more heat to deal with

- But this is where it is at...

jaysicle · « **Reply #14 on:** May 14, 2011, 10:54:18 AM »

Quote from: willib on May 14, 2011, 10:41:14 AM

Very nice jaycicle,
Norm will like the excercise bike, and i do too.
that flywheel has some mass to it too.
The mass really helps when pedalling , dosn't it?
built this one several years ago

Great stuff !

That is a moster willib. I love it.

ghurd · « **Reply #15 on:** May 14, 2011, 12:02:39 PM »

Wow!
Looks great. Very well documented.
G-

Norm · « **Reply #16 on:** May 14, 2011, 02:56:15 PM »

Great stuff, J.
You must have about 10 x the ambition that I have....your neat layout
staggers my imagination.
What do you average in watt-hrs. per day (I might have missed that
hidden in all your data)
My diet plan is simpler than yours....I weigh myself every morning,
if I weigh more I vow to myself to eat less. LOL
Also since I'm a diabetic and have a meter to check my sugar level
I try to keep my level down to about 140 (works for me)
Seems that I'm a breadaholic....if I can stay away from bread in any form
I can lose weight and keep my sugar level down ....and keep exercising.
But just pedal exercising alone keeps me from gaining weight and keeps
my batterys charged.

jaysicle · « **Reply #17 on:** May 14, 2011, 08:22:40 PM »

Hey Norm,

The other side of the room is not as scenic.

The power chart above is not as accurate as I would like in the upper end.
I only had an analog meter on it at the time and it was tough to keep pedaling at each constant speed.
The needle would slam passed the limit at each kick at the higher currents, and so the upper 2-3 numbers/points are averages (.707 of max). The chart above is with a 14 tooth driven sprocket. It is now 19 tooth driven.
Not catastrophic, since I believe the numbers in the usable range for the bike are more or less repeating today.

I had intended to record data again, and chart it with the 19 tooth driven that is on there now.
Today, after getting on the bike again with a clipboard - and with the goal to answer your question actually...
I recorded this...

Usually I ride for 40-50min. I cycle between the 1hour and 5 min. durations. When my heart rate is comfortable 120-130 for a few minutes, I 'get off of the bench' and push it a little harder - say 140-150bpm for the 5min. and back again. Sometimes I will go for a burst at 32km/hr 100W rate, but this would only be 3-5 times during the ride at a one minute duration each.

I would guess that I am somewhere between the 63W and 81W marks during the ride - at 28km/hr or 30km/hr. For 50 min run (0.83 hours) is about 60Watt-hrs per day. For 40 min run (0.66 hours) is about 48Watt-hrs per day (if my math is correct). I think you have mentioned that you noticed a difference between what you thought you were putting out (that doesn't sound right $:-\$ ) ahem... generating and what you were actually generating. Doc Wattson would be good idea for me as well.

I am totally open to improvements as well. I realize that using a DC motor would be something to consider for more output...
However, in the spirit of learning - I'd like to use existing parts and maybe wind and pour a new stator for ~$60 without the 1/8" plus 1/8" plexi glass. Maybe a slightly smaller coil ID with some more (10 = 10%) windings? Right now each phase is 1.8ohms, 100 turns of #20. Looking at the current stator, is there an obvious efficiency pick-up to be had? It seems I do not have a thermal issue yet...

As mentioned I am at about 1:1 with the 48W television. I looked into a small LCD unit that used a 120VAC to 12VDC Xformer, and running it directly off of the bank - but couldn't justify the overall cost.

dave ames · « **Reply #18 on:** May 15, 2011, 01:21:57 AM »

thanks for the look jaysicle,

super great stuff.. with a nice write up!

..does it ever stop raining there?

good call bringing those other 3 leads out..that gives us a bunch options and it's FREE!
we are getting a nice collection of ped gens now..and some guys are even using them

dave

ghurd · « **Reply #19 on:** May 15, 2011, 02:35:32 AM »

I need to formally apologise to Jaysicle for assuming he was a newbie.

This is one serious machine, and incredibly well documented.
The project is nothing like I expected.
G-

Norm · « **Reply #20 on:** May 15, 2011, 08:01:04 AM »

Quote from: ghurd on May 15, 2011, 02:35:32 AM

I need to formally apologise to Jaysicle for assuming he was a newbie.

This is one serious machine, and incredibly well documented.
The project is nothing like I expected.
G-

Jaysicle, what Ghurd says goes double for me.....newbie is a general
term usually only meaning new at posting on this forum.

Norm · « **Reply #21 on:** May 15, 2011, 08:59:07 AM »

Only have time to write a little bit right now.....its hard to explain but right now I have 2
NiCad batteries in series after resting all night total voltage 25.31
voltage after 30 seconds while pedaling crank speed of 60 rpm 28.56 (genny speed 660)
6 minutes of pedaling gives me 5 watt/hrs which would give me 50 watt/hrs.
potentially I could keep this up all day if not for distractions.....
voltage now reads 25.14 after 10 minutes rest. (about 1 watt/hr. input)
now .
What is your crank pedal rpm in the 50 watt/hr. range?

jaysicle · « **Reply #22 on:** May 15, 2011, 11:13:12 AM »

Dave,

Thanks for your kind comments, and actually reading the content... I will get a few tighter photos of each segment and post those later today.
It is still raining on and off, but the long term forecast looks a bit better now.

Separating the neutrals was on ghurd's advice. While I requested information on one of his controller kits, he offered several good ideas and next steps. The advice he provided (and the way it was delivered) instilled confidence in both his controller and this site.

You alluded to a bunch of options... I guess that another interesting step would be to wire a switch and build it into the bridge rectifier case to go from IRP to Star etc. and chart that output.

jaysicle · « **Reply #23 on:** May 15, 2011, 11:26:38 AM »

ghurd, Norm...

I am not at all put off by the term. Just glad to finally contribute.

jaysicle · « **Reply #24 on:** May 15, 2011, 12:06:12 PM »

Quote from: Norm on May 15, 2011, 08:59:07 AM

What is your crank pedal rpm in the 50 watt/hr. range?

I am at about 95 RPM pedal rate at 50watt/hr.

Pedal Crank = 40 tooth
Freewheel = 16 tooth
So, 2.5:1 at Flywheel.

Flywheel = 40 tooth
Driven sprocket on PMA shaft = 19 tooth
So, 2.1:1 there.

About 490 RPM at generator. This reads ~"28km/hr" on the bike. I was able to keep the speedometer attached to the flywheel and safely route the cable up to the display. Still need to cover the workings with the cowling though for a quieter ride. Actually, the generator bearings etc. combined is a little louder than the bike, and I could build something for that as well. I can hear the TV the way it is though, so it is not as if the thing is up at 95dBSPL when spinning. Should chart that... Should mount the generator and bike on aluminum rail/rack so it doesn't flex as much... (uhh, come back to the post jay...)

Started with 14 tooth on generator and 14 tooth on drill press to get readings.
Kept the 14 tooth as driven, without knowing how easy or tough it might be to push.
Thought that since I could stop the drill press by hand, I could generate a lot more torque with my legs.
Completely true, but for how long? When assembled, found it felt like a steep uphill above 22km/hr.
Was not comfortable going that slow at that physical resistance.
Wanted to be able to actually 'ride' the bike at somewhere near 100RPM pedal rate,
so targeted 22 tooth driven to get me to 100RPM pedal rate or '30km/hr' feel.
It winds up where it is because the local place I bought the sprocket from only had 19 as highest number with the 1/2" bore.
Now that I have had it for a bit, I am not sure I'd have liked the reduced output with 22 teeth/460RPM at generator.
Funny how that works sometimes.

Typing in 'all day' on my sheets may be a little misleading as well. One of the limiting factors is how long I can sit on the seat for. 40-50minutes is about all I am comfortable with, even with the modified pads for circulatory reasons.

wooferhound · « **Reply #25 on:** May 15, 2011, 01:05:47 PM »

I have added this Post to the FAQs section under the heading "How can I make a Pedal Generator"
http://fieldlines.com/board/index.php/topic,143675.0.html
It is the first link in the list there . . .

jaysicle · « **Reply #26 on:** May 15, 2011, 01:23:36 PM »

Here are tighter photos of the flywheel and generator shaft end bearing / rotor...

jaysicle · « **Reply #27 on:** May 15, 2011, 01:28:04 PM »

Continued... also includng Bridge Rectifier / Meter Box terminals...

Norm · « **Reply #28 on:** May 15, 2011, 01:33:20 PM »

Guess I'll have to hook the digital speedometer up again .
Also make a graph of the rpm actual speed and power maybe even open voltage.
With the ECM motor the power curve is fantastic....very sharp uphill curve from 660 to 680
(I'm wildly guessing) the WattsUp meter would read Wp75 to Wp95 (thats not average....but
peak.

A pedal rate of 95 would be difficult unless I switched to 36 volt batteries.
This is why I'm charging 24 volt batteries......
When I charge a 12 volt battery it is difficult to pedal faster than 30-35 rpm.
Guess I'll make a graph........
see ya later !
Norm.

jaysicle · « **Reply #29 on:** May 15, 2011, 01:34:30 PM »

This is the Main Load Disconnect from Battery to Inverter. There are 2X 100A fuses.

jaysicle · « **Reply #30 on:** May 17, 2011, 08:58:47 PM »

Quote from: wooferhound on May 15, 2011, 01:05:47 PM

I have added this Post to the FAQs section under the heading "How can I make a Pedal Generator"
http://fieldlines.com/board/index.php/topic,143675.0.html
It is the first link in the list there . . .

Took a bit for this to sink in. - I really appreciate that. I am new here, but renewed to push this project some more.
Not sure how much is attainable through changes to existing, but I will attempt them and chart them. Thank-you.

Next tangible: to complete and implement ghurd's controller into this set-up.
When I ride and don't consume anything, the voltage creeps up into bad ranges.
I can't wait to set the limiter, ride into it - see it trigger and dump - then post this stuff.

Suppose I should brace for sudden resistance drop when it kicks in

zap · « **Reply #31 on:** May 18, 2011, 09:18:22 AM »

Good pictures, nice write up, great pedgen.

Quote from: jaysicle on May 17, 2011, 08:58:47 PM

Suppose I should brace for sudden resistance drop when it kicks in

I have a ghurd controller on this setup,

from this post and it does a gradual turn on, nothing sudden.

ghurd · « **Reply #32 on:** May 18, 2011, 09:41:14 AM »

Quote from: jaysicle on May 17, 2011, 08:58:47 PM

Suppose I should brace for sudden resistance drop when it kicks in

No shock with a decent size battery. It takes power from the battery to hold it at a stable voltage, and you are pedaling into the battery at a stable voltage.
So no shock.

Shock comes from some of the goofy controller designs, which IMHO are not good for a pedal or wind generator... or anything else.
G-

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Author Topic: Bicycle Generator Project (Read 30359 times)