3D printed generator and how it works.
HTML-код
- Опубликовано: 26 ноя 2021
- For more information check out my website: fraensengineering.com/
Here you can see the material used (affiliate links):
3D Printing Filament: amzn.to/3zQRvzX
Copper wire: amzn.to/3OzclI4
Magnet: amzn.to/3nbv6Wx
In this video I build a 3D printed generator. It is driven by a gear ratio by hand. There are 8 pieces of magnets with a diameter of 15mm. The centric wave has a diameter of 12mm and is ~ 90mm long. For the 6 pieces of copper coils I used a 0.5mm painted copper wire. It is needed ~ 50m wire. The rotor has a diameter of 95mm. All parts were printed from PLA.In the video I used a much too strong lamp. As a result, the efficiency is relatively low. This should actually be slightly higher.
If you want to support me: paypal.me/FraensYT
Here you can download the files:: cults3d.com/de/modell-3d/vers...
or here: fraens.etsy.com/at/listing/14... 
Наука
![Moneybagg Yo - WHISKEY WHISKEY [feat. Morgan Wallen] (Official Audio)](http://i.ytimg.com/vi/kJamyq0WplE/mqdefault.jpg)
double output with metal plate, hidden gem😁. thank you doing the test and sharing.
Great design very usefull
Good work!
interesting project
Thanks for sharing
You are so genius man
Thanks for this nice comment :-)
Génial merci beaucoup pour le fichier également
Amusez-vous à construire. N'oubliez pas d'étiqueter les débuts et les fins des coils ;-)
This is really cool!!
Thank you. I am currently in the process of flanging the generator to a gasoline engine.
Thanks man good video
Very nice video, man
Thank you very much
very interesting project ! there's only two ways to loose efficiency, I squared R losses in the coil windings and mechanical drag (bearings, wind resistance etc), adding a soft iron core into the coils can be a mixed blessing, making diameter of the disks much larger would help in lots of ways
A soft iron core would of course bring a lot of efficiency. However, you get a "cogging" moment. This is not desirable for wind turbines.
If you increase the diameter, you also have expontentiel increasing costs. Large magnets cost a lot. More copper would be consumed -> higher electrical resistance in the windings....
This would increase the voltage, but I doubt that the efficiency would improve.
I must also say that I am not a specialist in the subject.
Translated with www.DeepL.com/Translator (free version)
Nice work! Which software did you use for the CAD design?
gd job
That is pretty awesome, I can couple that with my Stirling engine, thank you =)
Good idea. That would have to be tested to see if it works.
@@FraensEngineering Why did you spread the coils in this triangular shape ? How exaclty does this improve the flux ?
The induction function best when the magnet crosses the wire at right angles. This is best given by the triangular shape.
@@FraensEngineering Ah I see, thank you.
Is there a way to 3d print a power generator that will generate electricity for your 3d printer? Electricity bills are expencive af here in Germany rn
Could I get the different screw and bolt sizes of the generator. Also where could I get the axle for the generator
I like your design approach. I think it would make a better brushless motor than a gen. I believe rotor magnets and coils should be as close to the shaft as possible to cut down on on drag when you apply a load for gens with the opposite idea for motors. Clean looking pancake though.
Hi, the generator is an often used construction for wind turbines in the DIY area. The coils are as close as possible to the pivot point. The size of the coils depends on the size of the magnets. The magnets should move past the legs of the coils. If I want closer to the pivot point I would have to use smaller magnets. The generator works best with rectangular magnets. Then you can optimize the size of the coils.
Translated with www.DeepL.com/Translator (free version)
I just checked out your channel. You make very cool videos.
@@FraensEngineering Thanks, I guess what I mean would be to use neodymium bar magnets parallel to the shaft as close as possible in a halbach array. I'll eventually post what I mean but I'm currently working on other ideas. Your channels has some good content as well.
I'm also working on a project right now. It will be something that everyone knows but nobody knows how it works. Halbach array sounds good. I have to take a closer look. Thanks for the tip.
@@FraensEngineering I'm subscribed so when you drop that video I'll definitely check it out, you got me interested. What could it be?
any good book on how to choose the magnet and the coils?
I mean If I need a sinus with a 20v amplitude and a 2A current, how do I know which diameter? loop numbers? wire diameter? magnet force? magnetic field shape? to use?
Hi, here is a great calculation tool for designing disk generators: www.kleinwindanlagen.de/Forum/cf3/topic.php?t=2825
Спасибо, было интересно.
Я не знаю русского, но гугл переводчик :-)
Я рада, что вам понравилось.
@@FraensEngineering you got it right)) best wishes and further growth to your channel))
Excellent work. Would 3D printed generators be robust enough for use in wind turbines? If so, this has fantastic potential..
Hi, I have paired my generator with a petrol engine as a test. If the engine didn't vibrate so much it would work. On a wind turbine, I think you should find a way to not connect the probe directly to the generator. I would not direct the forces to the 3D printed parts. With a longer shaft + a bearing at the front and rear, that should work. The generator could then be hung up using rubber buffers.
No. Not strong enough for a useful sized turbine. Fiberglass and aluminum are better choices.
Thank you for this model and video. I have so many questions. What are the numbers on the charts that are separated by a comma. Do you plan to experiment more with Printed Generators? I am curious about the shape of the wire coils. Would you get better output with rectangle shape instead of the trapezoid shape used here? Also if you added two more discs (another set of coils and magnets). Would you get more power at a lower torque?
Hello Aaryn Ellsworth Aaryn,
I do not think that a rectangular shape increases performance. Through the round stator, trapezoidal coils fit much better. The current is induced on the legs of the coil. With a rectangular shape you need more copper. It is important that the coil / magnet number 3/4 remains. So you can, for example. 6 coils / 8 magnets or 9 coils and 12 magnets etc. use. Here is a cool tool for calculation: www.kleinwindanlagen.de/forum/cf3/topic.php?t=2825
People in many other countries use a comma instead of decimal point :)
Nice work! You could further increase efficiency by adding a metal core to each coil, it will allow a higher flux than you can currently get with an air core.
With a metal core, there would be a locking moment. That is why a metal core is not well suited for a wind turbine.
This is a tricky topic. The metal does not actually do anything to the efficiency directly. The efficiency is limited by friction and heat generated in the coils because of IR (current resistance) losses.
It feels like you are getting more out of the motor but the output is still a function of the number of magnetic flux lines crossing coils per unit of time. If you add iron cores ( you will get detecting or cogging which as @Fraens said makes a windmill harder to start at low wind speeds) but you can get just as much power out without iron cores. You just have a lower concentration of magnetic field lines so you have to spin it faster. It feels like you get more power out because your arm can only spin it so fast.
You could argue that additional gearing to get higher rpms will have additional friction including wind resistance but I don't think that is what most people mean when they say add iron cores. The same thing holds for the strength of the magnets. Neodymium magnets don't make motors stronger.
Certainly higher flux. But it just feels like it is more efficient at least to the first approximation. See my comment below. It is not obvious. I have had long arguments about this even with engineers.
One thing that helped me think about it was to try to answer the question "What determines the amount of power that a generator can produce?" Hint: it has nothing to do with the magnets.
Putting iron or steel will slow it down it flows because magnetic poles on the rare earths are aligned with the 2 rotors so the flux flows between going through the coils almost no friction loss !
@@GeorgeAlbercook I read somewhere that the core only allows you to rap five times the amount of coil on the same size core. So unless your adding more wire it doesn't realy make a difference
@Fraens Hi,
I am currently rebuilding your project. But I have difficulties with the coils. I have understood your circuit diagram. But which end of the coil is A and which is E?
Regards
Basically, it doesn't matter what you define as A and B. It is only important that you do it the same for all coils. For example, A is always the beginning of a coil. So the inner wire.
Hi, If the coil thickness is increased to 10mm will it get more output? Since there will be more turns...
This would increase the distance between the magnets. This weakens the magnetic field. I don't think it increases performance. More windings increase the voltage. The ohmic resistance is increased by more wire. The overall output remains the same. Basically, the magnets should be as close together as possible. The air gap should also be kept as small as possible.
good job. What are the wire and magnet sizes?
It's all in the video description ;-)
I always dreamed about a bicycle without the chain!
Like you spin pedals connected to the generator and charge the battery, then through wires energy goes to the motor.
That's a cool idea. Can this work ;-)?
@@FraensEngineering Yes! Thousands of tons of oils are used every year to lube bicycle chains, contaminating the nature. Also it makes our hands and clothes dirty.
There are millions of electric bikes, but most of them have chains.
Why???
First, I would tap the required speed. You already need a minimum speed to come to 12V / 24V. This depends on the number of turns of the coils. If you have more turns you get a higher voltage. With the same size of the coils, the copper wire would have to become thinner. This increases the ohmic resistance. This makes the efficiency slightly lower. A bike motor has about 250W. The generator would have to be built a bit larger. As a result, the generator also gets more mass. I think it will have a reason that does not buy such bikes. Maybe you could build something with supercondensors ..... ???
This can be done. It would be a very difficult to pedal bike. Chains are 100% efficient. Going from a generator to a motor is about 70% efficient. So you'll lose 30% of your input power to heat.
Hi I could you tell me what else I have to buy, beside copper wire and magnet. such as the center metal bar and the 3 metal bar for the bolt?(sorry I am not sure it is correct word)
There are 8 pieces of magnets with a diameter of 15mm. The centric wave has a diameter of 12mm and is ~ 90mm long. For the 6 pieces of copper coils I used a 0.5mm painted copper wire. It is needed ~ 50m wire. 2 pieces of needle bearings with dimensions 16x12x10 are required.
Nice, but why the efficiency is very low, i expected that gen can get at least 70-80%
The efficiency in the video is not entirely correct. the efficiency would have to be measured with a variable resistance. The efficiency in the video only refers to the light bulb. So it doesn't say much.
My 10 year old son is trying to build this for a school project. Thanks for providing this video!
What is the dimension for the central rod and where can one be purchased?
I'm going to create an assembly drawing today and upload it to Thingiverse with all the relevant dimensions.
Her son has chosen a great project 👍
@@FraensEngineering thanks! He will be thrilled
Hi, ich habe eine Zusammenbau Zeichnung erstellt und auf Thingiverse hochgeladen. Ich denke diese sollte recht hilfreich sein.
Thingiverse: www.thingiverse.com/thing:5148004
@@FraensEngineering Super helpful. Danke!
Hello, from minute 3 in the video I recorded the circuit diagram. The numbers are the coils clockwise. You will see the numbering at minute 2.30.
"A" means beginning of coils, and "E" always means end of coils.
A1-A6=beginning of the respective coil
E1-E6=end of the respective coil
As an example for phase 1: A1 is combined with A2 and A3. E1 is merged with A4. E4 is then the connection to the rectifier.
So there are always 2 coils connected in series -> coil 1+4 / coil 2+5 / coil 3+6
In this work it would be good if the coils were labeled before installation.
Here's a nice drawing of the wiring:
www.daswindrad.de/forum/viewtopic.php?f=24&t=1129
At 1:41, How about the 2nd rotor what is the orientation? Do the magnets place in such a way they repel to the 2nd rotor? Or attract? If attract, did you use glue to prevent them from joining?
The magnets attract each other. The 3D printed disks are designed in such a way that there is a small step so that the magnets cannot contract. No glue was used.
@@FraensEngineering Hi how did you measure the RPM? From the shaft?
The RPM was set on the lathe.
@@FraensEngineering Hi when I place the magnets, ghe magnets sticks to the other side of the rotor (rotor 2) should I use glue to prevent this from happening
Hi, I don't quite understand what you mean. Do you think the magnet will pop out of its hole and stick to the magnet next to it?
You have to put the magnets on both discs or plus-minus-plus... into the holes. You can see that in minute 1.35. Now, if you hold the two disks together, attract the disks. However, the magnets cannot get out of their holes because there is a step in the discs.
If we just have 50 kWh power wall energy storage, self running generators would be viable for living. Even if it's just a small amount of energy, if it's continually putting out energy into power walls, we can use them.😎👍
Unfortunately there is no such thing as a self running generator.
@@columbustalley330 look up the alternator magnet combo version of self running generators. And it can be modified to put out even more energy. The powerful magnetism would both feed itself and power the self running generator.
@@columbustalley330 once you go down the tech rabbit holes. Take the red pill😎. Or keep believing the things aren't able to be far better. Did you know that two different people from different countries, came up with ways to make the first EVs run forever. Those people were disappeared. Petty humans.
@@caseyford3368 I've seen it all believe me. There is no method for defying the laws of thermodynamics. Link me a video of a machine that you believe breaks those laws and I will explain why it doesn't.
use supercapacitor to keep energy.
In conclusion 6:58, does metal plate on axial motors also increase the performance? not axial generators.
Most likely yes. But I don't know exactly. The performance could be increased again if you had a metallic core between the coils. But this would result in a "cogging moment". For wind turbines this is rather undesirable.
I have printed he generator i read at the youtube that 0.5 koper to use bud how many turns pro coil i like to use 0.6 mm
Hi, unfortunately I can't tell you the number of windings. It is important that you make the same number of windings on all coils.
If you have a water mill, can't you combine both of those for free energy?
Unfortunately I don't have a water wheel. The generator could also be used for a wind turbine. The efficiency in the video is unfortunately not correct. I estimate the efficiency to be ~ 60-70%. I think a waterwheel would need a gear to get up to speed.
halback array for magnets !!! use
If I Tripple the rotor and add another stator would the output double as well?
I think it would be better to increase the diameter and double the number of magnets/coils. I think you can achieve four times the performance with twice the material costs. You should take a closer look at that.
@@FraensEngineering But the idea of having tripple rotor and another stator can also be done right? If you want it to be compact?
@@FraensEngineering also sir, did you compute for the shaft size specifically the diameter or you just made it that way?
I chose the shaft diameter based on the bearings I had at home.
Have you tried testing it on a no load condition? I am curious what would the voltage be at 950 rpm.
200rpm=2,8V / 330rpm=4,2V / 550rpm=6,8V / 950rpm=12,7V / 1500rpm=20V / 2400rpm=30V
@@FraensEngineering was expecting a higher voltage since its wye connected. Hi is the metallic plate included on this? Or this is the result for without?
I think on this scale with round magnets and steel disk, is not expected more. I have approximated the magnets as much as possible and used a reasonable number of coils with respect to the number of windings.
Technically, everything should be fine.
Suggestions for improvement are gladly accepted.
Without metal plate: 200rpm=1,9V / 330rpm=2,8V / 550rpm=4,5V / 950rpm=8,5V / 1500rpm=13,3V / 2400rpm=20,4V
@@FraensEngineering would their be any difference if it were to be connected in series rather the 3 phase?
Very cool. Looks a lot like something I made with knex. But your is nicer haha. I've been making a similar axial flux motor/generator lately. Check it out. And keep up the awesome work
Hi, you have built a very great generator there. Your winding looks interesting. Looks very professional. Have you tested it yet? Do you have a wind turbine or a water wheel?
In 2 months these is what I learnt as beginner while building own generator.
1. coil to magnet ratio, 3:4 is the best
2. thicker copper more Amp less Volt, the opposite for thin copper
3. 3 phase over single phase
4. magnet thickness must be equal to coil thickness
5. iron metal backplate boost the output
6. to make lower rpm generator, increase coil/pole number
7. magnify magnet strength with Halbach magnet arrangement, >40% generator output
8. what else?
8. The distance between the magnets should be as close as possible.
9. a metal disc should be used to direct the magnetic field.
@@FraensEngineering lol just now another new discovery for me, with halbach magnet, the backplate iron only gives very tiny improvement, can completely skip them, wasted some 60 buck ordering them😅. based on this ytuber experiment ruclips.net/video/j-XNeij_KpU/видео.html
I am also building a generator based on Fraens's model and would like to add the following:
10: inner coil diameter at least as large as outer magnet diameter.
11: rectangular magnets are more effective than round ones.
@@matthiasdollinger6441 good points. sadly no.10 is something I've to closed one eye on for now because I'm already 50% in progress with my 2nd attempt on this axial flux gen. my inner coil dia is about 30% less than magnet diameter. based on my 1st generator my 2nd gen will work fine but likely losing little efficiency there, hopefully other improvement will make up those loses.
My 1st axial flux is 10cm in stator size, 9:12 coil to magnet ratio, I'm happy it does generate power (even with my sketchy construction) but they're very inefficiency. my second build now is 25cm in stator diameter size, 30:40 coil magnet ratio.
my bitesize aim is a handcrank generator where I can spin them for few minutes and store the energy in a supercap powerbank, the stored power hopefully have enough power to light up my room for a day.
Good luck with your build.
wow you're pretty smart don't ya jeje
Funny comment. Many Thanks :-)
👌🍋هندسهة ⚖️ جنون 🌍
What kind of metallic plate you attached at the back of the generator?
I used regular S235 3mm steel plates.
@@FraensEngineering Thanks bro
@@FraensEngineering Can I substitute it with an aluminum plate instead?
The steel disk is used to conduct the magnetic flux. Since aluminum is not magnetic, it will have the same effect if you do not use a disk at all.
Have you tired bifilar windings
No, only one wire was wound.
عبقري
Thank you from Austria :-)
Idea - 3D print 2.0 - Bake the thermo bakable 3D printed plastic in the oven for much more strength. There exist such doe plastic which you bake in the oven. Tougher materials that way //Per
Cool idea! Or you print with a different material ;-)
Can you share the 3d model to try it?
Hier kannst du die Teile herunterladen: www.thingiverse.com/thing:5148004
bonjour et merci mais le fichier est inaccessible comment faire ?
Hello, yes I know that. You have to go to "Thing Files" and then download the models one by one. Unfortunately, Thingiverse is no longer supported by MakerBot. The site has a lot of bugs.
Would you sell all the parts in a kit ? How much ?
Hello, I am currently not selling kits. Should my channel be a little bigger, I'll think about it.
how much of power can i generate ??
Check out the performance chart in the video.
Will the magnet stick to the steel plate?
Yes it sticks to the steel plates.
@@FraensEngineering Hi any tips on how to make the efficiency better? I was expecting a higher efficiency. Or is it because you tested it with a higher load?
Hello, I estimate the efficiency to be around 60%. This is a guide value for disc generators. In fact, the efficiency can only be determined for one load at a time. This varies depending on the load. I did a poor job of portraying that in the video.
You could get even more out of rectangular magnets. Then the area traversed by the coil would be larger. Round magnets are not ideal here.
@@FraensEngineering Last question, I have an iron PLA do you think it can be an alternative to steel plate? Or a steel plate would be better?
I don't think that steel PLA is an alternative. A soft iron plate would be best. Steel isn't really the best either. Soft iron is used in transformers and motors.
Is this axial flux generator?
Yes ;-)
I was doing some test on low drag generators. I found out that if you turn the coils side ways (so that the magnetic fields of coil core is perpendicular to the magnet field lines) you basically eliminate the drag on the rotor. But at the cost of getting half the voltage. After care examination using the right hand rule I realize that half the coil is is fighting against the other half and the a net voltage is shown. My plan to fix this was to add the same magnet pole on both sides of the coil. So instead of north then opposite to that is south. You would have north then opposite to that is north. Then the adjacent is south and opposite to that is south. Then north north, south south etc. By the right hand rule this should allow close to the full power while still eliminating drag. I didn't get to test it cause it's hard making a rotor out of cardboard with minimal clearance on both side of the coil. If you could test and post the results it will be appreciated
Hi, I can not follow you. Do you mean the coils would have to be rotated 90 °? If you are always south/south - north/north at these coils/magnet arrangement, the inductance in the coil will lift up. This creates no current flow.
There are always 2 coils connected in series. Through the 4: 3 (magnet: coil) arrangement, the magnets are always guided via the legs of the coils that a current flow comes about.
Currently, I am to assemble the generator to a gasoline engine. If that works well, I will build a larger generator and load a car battery. An inverter can then operate 230V devices.
That is the plan. Let's take a look if that works like me think that :-)
@@FraensEngineering yes the coils would have to be rotated 90 degrees. So picture a normal axial generator where each coil is sandwich between attracting north and south magnets. Now rotate the coils 90 degrees and sandwich them between repelling magnets. I know the coil generates power at 90 degrees even if it's not sandwich between magnets and that the voltage generated is usually near half that if the same coil was not at 90 degrees. And by examining with fleming's right hand rule it makes sense, because half of the coil is generating power in one direction and the other half is generating power in the other direction. So a net voltage is produced at the coil terminals. The voltage is not zero because the half of the coil further from the magnet generates lower voltage. The 90 degrees orientation almost has no drag. So the question is can this orientation be improved using repelling sandwich magnets to compete with the normal axial design
What is the shaft made of? What kind of material? Brass?
I used brass
@@FraensEngineering Thanks bro
@@FraensEngineering Will it be okay to share your email so I could ask further questions?
Please ask questions here on RUclips. Thank you.
@@FraensEngineering How did you get the measurement for the inner diameter and outet diameter of the rotor? Or its just a random placement?
How much turn per coil???
I didn't count them. Simply wrap it up ...
@@FraensEngineering ok thanks
And because it's attached to a power wall, it would still be traceable for energy companies. There would just be far more clean energy to monitor.
how to buy
www.etsy.com/at/listing/1430634094/3d-printed-generator?click_key=81136aec6579208dd0c16aa083356ae28088753c%3A1430634094&click_sum=e2ea4b84&ref=shop_home_active_7&crt=1
toi muon dac bo khung lon hon duoc khong
You can do it. However, you need to consider a few things. You should make the base frame a little more stable. With a larger diameter, I would also use larger magnets.
@@FraensEngineering tôi muốn đặc bạn làm được không
Unfortunately I don't find the time to do it at the moment. I currently have some projects that I want to realize.
Magnetic flux
Not flow
!!~~~~
Not on thingiverse!!!!
You missed the mark.
Only I know the way.
Ok, well then...
Do you want to explain the way?
"3D Printed" - you know, with machined shafts from a metal lathe. Cool project, but misleading title as you need more than a 3D printer to build this thing.
OK. I don't think the title is failed. How should you build a generator without magnets, bearings, shafts, threaded rods ...?
Does it say "fully" or is it a challenge to use nothing else ?
..no
Gotta agree with ya. When it says its a 3D Printed generator then that would mean its entirely 3d printed, not a generator with 3d printed parts
Very bad performance ! Without experiment you did everything you wasted money and time
Definitely coil shape and size are wrong
Number of turns too
You should not upload this on RUclips
This will misguide the people
Please offer constructive criticism. Give suggestions for improvement. I think other people are more helped by this.
I do not know if you have already dealt with disk generators. Apparently not! The coil shape is built exactly the same for such generators.
People think these are great generators but they lack efficiency. If it was efficient it would blow the bulb. There are ways to make them efficient, it requires a slightly different design.
Edit: sigh, completely wrong in engineering of this.
Please make a constructive suggestion to improve efficiency. I think that would interest everyone. Disk generators for wind turbines are built like this.
Such comments are of no use to anyone.
I suppose you engineer motors from scratch for a living then? We are all humbled by your wisdom. /s
Hate! Models is for Cash so Nah! dont buy
50W ?
In the video you can see a performance test
Would you sell all the parts in a kit ? How much ?
Hi, I'm currently concentrating on my projects to produce new content. If my channel has a greater range, I will think more steps. Maybe then I could sell kits. But until the time has come, I will not sell any parts. Maybe you know someone with a 3D printer. You can download the parts from Thinkiverse.
Magnetic flux
Not flow