Author Topic: Pedal Power station V2 Begins  (Read 7740 times)

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remowylliams

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Pedal Power station V2 Begins
« on: February 22, 2011, 11:27:53 PM »
Hello everyone, last year I finished my Pedal power station with some good success.
As it turns out


This machine made almost entirely from junk parts (except the power outlet, the power
switch, and the 12 Ndfeb magnets). The key aspect was using a Microwave Oven Transformer.
as the power winding. I can generate ~ 250 watts of power out of this machine pedaling.
Now it's true I can't do it for long, but over all it's pretty easy to put out useful power that
can be stored or used directly.

As it stands, I was very happy with this. but you always get a feeling that a good idea can
be done one better. To this end, a friend has given me his old exercycle. This machine has
almost exactly the same magnetic resistance system as the old one. I've decided to build
the machine again but use some different configurations for coils and magnets to try and
maximize the power out of this.

I'll post more as time goes by and I make progress. The nice thing about this new pedal bike
is that it has a heartrate meter built in, and a sturdy riser, that should provide a fine mounting
platform for a fan, or a tv screen or whatever I want to put on it. Maybe a 2 meter rig.

Lots of possibility and for this it will all just be a question of having fun.

Thanks for your  time reading this.

Remo

zap

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Re: Pedal Power station V2 Begins
« Reply #1 on: February 23, 2011, 12:25:26 AM »
Hi, welcome to fieldlines.

Interesting design.

I can generate ~ 250 watts of power out of this machine pedaling.
Now it's true I can't do it for long...

How long are we talking about, and what's the average output?

remowylliams

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Re: Pedal Power station V2 Begins
« Reply #2 on: February 23, 2011, 06:50:16 AM »
Average is about 150 watts. I sustained that for around 30 minutes.

You can't see it well in the pictures. I have more that would show the front panel,
but this machine runs the output of the primary from the microwave oven transformer,
into either, a salvaged 500 watt ups transformer or a 25 A, fullwave bridge. So I can
get wall current or direct current. (It wasn't till later I realized I could have had both.)

AC wise I could output about 200W, voltage was 125v @ ~ 1.7 amps and 75hz
DC wise I had 16.5V @ 15 A.

Of course the harder you pedal the higher the output, so this thing can peak pretty easily.

I have a short 30 second video of me pedaling and powering 300 tiny incandescent Christmas lights.
they brighten and darken as my output varies. Which is why I have the DC side.
 
Sorry I got lost in the numbers. I watched a dvd by pedaling and powering a power inverter,
that in turn ran the dvd player. It's one of those that has it's own 7" display as well.

To level the output and give me a chance to coast now and then, I built a NiCd battery
pack that can regulate my output to a point that the inverter won't shut down if I pedal
too fast or too slow. All in all not the most efficient way of doing this, but I have only
half a shoe string to built this on and the point had been to build out of junk one could
find in a junk yard, a machine that could produce useful power.

I never realized till I cracked open my second MOT how easy it is to open the core of
the transformer so it could be used as a power pickup. You grind away 2 thin welds
and the bottom pops off clean as can be. The primary winding is right there in front.

You gotta watch out for the secondary of course. it's going to produce about 560-1000 v
I actually wired a 13w fluorescent bulb to this since the current is quite low and it
tells me I'm up to speed. :)

A list of the parts pretty much are here:

Pedal Rate ~ 120 - 150 RPM

Parts Used: 1 ProForm PFEX-70170 Exercise Bike.
1 Panasonic 1200w MOT (Microwave Oven Transformer)
12 2" x 1" x 1/2" N42 Magnets.
2 blocks of 2x4 as a standoff and mounting for MOT.
1 25A fullwave Bridge Rectifier.
6' #8 stranded utility cord.
1 500VA ups step up transformer. (scavenged from a junkups, this
was only to get direct wall current from the machine, which is not nearly as
efficient as we all might hope. See the power difference. between AC and DC)
2 17" long 5.5" diameter hose clamps.
1 bottle Gorilla Glue
1 roll ductape to fix the magnets to the flywheel, wrapping around
the outside of the wheel.
12 Magnet separators and packing foam peanuts to keep the magnets
seperated evenly on the flywheel.
1 Wall Mounted AC outlet.
1 20A 3 way light switch (for choosing AC or DC output)
1 set of post binders for dc output connections.


Norm

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Re: Pedal Power station V2 Begins
« Reply #3 on: February 23, 2011, 07:41:13 AM »
Hi....did you see my poll ?
http://fieldlines.com/board/index.php/topic,144394.0.html
Got a little information, been doing exercise bikes with generator
for a couple of years.....
http://www.los-gatos.ca.us/davidbu/pedgen/green_virtual_gym.html
We could use some more members ??
More later.....
Norm.

remowylliams

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Re: Pedal Power station V2 Begins
« Reply #4 on: February 23, 2011, 09:28:37 AM »
Hi....did you see my poll ?
http://fieldlines.com/board/index.php/topic,144394.0.html
Got a little information, been doing exercise bikes with generator
for a couple of years.....
http://www.los-gatos.ca.us/davidbu/pedgen/green_virtual_gym.html
We could use some more members ??
More later.....
Norm.

Answered your poll.

And as for your los-gatos site, yes I've visited it many times over several years.
I went through several PM motors trying to get satisfactory power output
to no avail. I had trouble with mounting stability and such.

I was just about to pickup all the pieces of my exercycle and throw it away.
I'd had it about 2 years for this project, when driving home I saw on a curb
this microwave oven. I thought how sad it's parts can't be used for more things,
and that's when I realized the high current windings and thick core of the transformer
would make a terrific power pick up if I could get at it.

Then it was just a matter of finding powerful magnets and I probably went overkill big time
with the 2x1x.5 N42 magnets but it got the job done.

I'll have a welder soon, so I should be able to do more with this design.

Best wishes.

Remo

Bruce S

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Re: Pedal Power station V2 Begins
« Reply #5 on: February 23, 2011, 09:35:46 AM »
Average is about 150 watts. I sustained that for around 30 minutes.

All in all not the most efficient way of doing this, but I have only
half a shoe string to built this on and the point had been to build out of junk one could
find in a junk yard, a machine that could produce useful power.

Remo;
 I'd say from having found a way to reuse a discarded microwave and build that beauty it's 100% efficient  ;D

I look forward to seeing the next build too.

Welcome to the board

Cheers;
Bruce S
 
A kind word often goes unsaid BUT never goes unheard

ghurd

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Re: Pedal Power station V2 Begins
« Reply #6 on: February 23, 2011, 09:39:46 AM »
That is the first time I saw someone actually do it that way.
I considered the concept.

Adding a second transformer, or more, would increase the efficiency.
Careful placement of the additional transformer could reduce the cogging.

Cool machine!
G-
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remowylliams

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Re: Pedal Power station V2 Begins
« Reply #7 on: February 23, 2011, 10:12:42 AM »
That is the first time I saw someone actually do it that way.
I considered the concept.

Adding a second transformer, or more, would increase the efficiency.
Careful placement of the additional transformer could reduce the cogging.

Cool machine!
G-

Thanks much for the kind comment. You can get the PDF I made of this here:

http://www.shires.org/~remowyll/pedalpower.pdf

It shows the machine closed up as well and with yours truly pedaling just to light the little light in the console.

With the new cycle I'm definitely going to try multiple coils. the trouble of course is doing so in such a way they
are couple-able I need to build a mounting rig so I will be able to move the cores so they're phases are useful.
The cogging on this machine is Huge at 0-5 rpm It takes about 90 lbs just to get the flywheel going. Which is no
problem for me. But it is funny seeing someone light push themselves out of the seat when they try to start it.



Remo
« Last Edit: February 23, 2011, 10:16:38 AM by remowylliams »

ghurd

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Re: Pedal Power station V2 Begins
« Reply #8 on: February 23, 2011, 10:29:13 AM »
Ah...  The microwave transformer's secondary winding is not being used at all!
Get it out of there.  The coil will create some drag even when unloaded.
Plus that will increase the efficiency just because the 13W bulb will be out of the equasion.
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zap

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Re: Pedal Power station V2 Begins
« Reply #9 on: February 23, 2011, 10:34:05 AM »
Nice write-up on the project remo.
It seems few even do projects and even fewer document them as well as you have.

remowylliams

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Re: Pedal Power station V2 Begins
« Reply #10 on: February 23, 2011, 11:12:00 AM »
Ah...  The microwave transformer's secondary winding is not being used at all!
Get it out of there.  The coil will create some drag even when unloaded.
Plus that will increase the efficiency just because the 13W bulb will be out of the equasion.
G-

Hi Ghurd,
 yanking it out is something I will do down the road. The load it puts on the unit over all
really is pretty small. mostly because the coil is so far from the flux of the magnets, it's only
noticeable if I short the hv terminals do I feel the load. But yes every little bit helps.

Thanks for the comment and idea.

Remo

remowylliams

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Re: Pedal Power station V2 Begins
« Reply #11 on: February 23, 2011, 11:14:53 AM »
Nice write-up on the project remo.
It seems few even do projects and even fewer document them as well as you have.

Zap,
  Thanks very much. It's the first project I've ever documented to any extent.
Partly because most of my projects are just toys. But this one was and is special to
me. I owe it mostly to watching 'Gilligan's Island' I always wanted to build something
where the energy I put into my exercise went to something other than sweat.

This new version, I'm going try and document better still.

Thanks again.

Remo

ghurd

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Re: Pedal Power station V2 Begins
« Reply #12 on: February 23, 2011, 12:01:47 PM »
The load it puts on the unit over all really is pretty small. mostly because the coil is so far from the flux of the magnets,

The flux in the LV coil is traveling into the center leg of the transformer's E, then out through the end legs.
The laminated core carries the flux from the center 'North' neo to the 2 'South' neos beside it.
The HV coil is getting the same flux as the LV coil.
G-
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remowylliams

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Re: Pedal Power station V2 Begins
« Reply #13 on: February 23, 2011, 12:30:05 PM »
The load it puts on the unit over all really is pretty small. mostly because the coil is so far from the flux of the magnets,

The flux in the LV coil is traveling into the center leg of the transformer's E, then out through the end legs.
The laminated core carries the flux from the center 'North' neo to the 2 'South' neos beside it.
The HV coil is getting the same flux as the LV coil.
G-


Mayby you're right. But previous tests I did showed the flux was pretty small at the end of the center core. I'd cut my first MOT apart to test flux penetration. I have come up with a different orientation for the magnets that I'll try soon. But right now, I'm waiting on my tax return. Then I'll be ordering up 12 2"x2"x1/4" N42's as well as 7 more 2"x1"x1/2" magnets.

The reason I'm even messing with this, is the power factor is much lower than it could be due to how far apart the magnets
are set. As you can see in the picture of the rotor, I have the magnets seperated almost an inch. This causes the distance
between peaks on the sinewave to be pretty far so the over all power is less than an idea sinewave and sucks when
I try to drive an inductive load like a AC fan.

I have to try to keep the rpm's low because right now the rotation speed will waltz right out of the frequency range of the core.

But rest assured the new version will try a lot of different things.


Thanks for the info.

Remo

ghurd

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Re: Pedal Power station V2 Begins
« Reply #14 on: February 23, 2011, 12:46:19 PM »
Not sure I follow "previous tests I did showed the flux was pretty small at the end of the center core. I'd cut my first MOT apart to test flux penetration".
Breaking the flux circuit path redirects the flux.

The perfect spacing for the magnets is one over each leg of the core (link)...  but the cogging will be as stiff as welded bearings?
2 or 3 transformers with the magnets lining up at different times than the first core will help.

I did not have a decent way to hold a 10~20VA core and rotating neos to get any decent tests.
This should be the 'best' way for power output, and the strongest cogging too.
http://www.otherpower.com/images/scimages/2050/TrnsfrmrGen.jpg

G-
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