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Post by Marathonman on Jun 25, 2020 19:12:28 GMT -6
Well my day was just to full, almost got it finished. lots of 12 volt wiring for fans and display. through all this mess i forgot the 12 volt switch for the display as it is needed to switch from voltage to current display. i was also working on our van camp with ambient lighting for the camp sites but that is a whole different story. will post pic when lighting is installed on ranch house. here is pic of power supply. Regards, Marathonman
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Post by Marathonman on Jun 27, 2020 21:14:51 GMT -6
Finished up the 12 volt fan circuitry and tested with 12 volt supply. everything is perfect, all fans just humming. the 40 mm push pull fans on each end of the power resistor worked out very well with good airflow for small fans. i still need to cut air holes behind the intel bridge rectifier heat sink to pull in cool air with exhaust on left side of unit.
still short (6) 10 awg spade connectors coming from the step down transformer to both bridge rectifiers then it will be time to fire up this baby and test. then comes part G controller to get finished as i have all the parts.
Regards, Marathonman
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Post by Marathonman on Jul 6, 2020 17:11:06 GMT -6
Well i was finally able to get both wires through the center hole of the brush holder. i had to drop down to 12 Ag to do it though but the resistance of such a short piece is nothing. it was quite easy so then i have the part i need to 3D print i can easily take it out to assemble. The third pic is some filter material that will be great for the power supply. after holes were drilled i have so much more air coming through. perfect repurposed intel heat sink. transformer is finished drying and will test with Variac tomorrow. Regards, Marathonman
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Post by Marathonman on Jul 6, 2020 17:24:28 GMT -6
Ready to do it's job displaying voltage and current. Regards, Marathonman
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Post by Marathonman on Jul 11, 2020 18:50:28 GMT -6
Update on power supply;
Bad news unfortunately, the guide i posted about building a transformer is wrong. when i powered up my power supply i surely got 12 volts out but the 100 volt side was completely saturated to the point of heating up the transformer and the EMI filter so much so that it softened up the resin bobbin. i blew the 12 volt repurposed intel fan on the heat sink but the twin push pull fans on the power resistor and volt/amp meter survived as they are 24 volt capable.
200 winds are way to much as i reviewed my notes including the loop count on the same size MOT. 100 winds is clearly enough so if you are following this guide please halt all building and reconsider these findings. so now comes the fun part of dewinding the transformer to meet the new specs and replacing blown or nearly blown parts.
as i have always said do not follow everything on the net unless you test it which i did and it failed miserably. good news is it will get fixed the right way and move forward in my build.
Regards, Marathonman
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Post by Marathonman on Jul 15, 2020 19:38:26 GMT -6
Well finally got my 3D printer squared away with a BL Touch and is connected to an Octoprint print server. man i tell you life is much better having these in your life. i finally printed out the bearing holder with the first totally no good but the second one was very sturdy. the pics below are the bearing holder 3D printed with the bearing in it's rightful place in life. this finally allows me to assemble my inductor controller. you have no idea how happy i am to get this printed. new motor, new slip ring, new brush's, i am ready to build the most adjustable active inductor controller on the planet. who is ready to see this as much as i am. Regards, Marathonman
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Post by Marathonman on Jul 16, 2020 16:18:40 GMT -6
Printed out my bobbin design today. i had designed it in emachineshop, export in STL to cura then uploaded to octoprint. the end cap was 1/64 th of an inch over sized so the fit of 128 th of an inch all around was absolutely perfect. it is ready to be glued then wound. i think i am going to round the corners first to ease winding. Regards, Marathonman
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Deleted
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Post by Deleted on Jul 16, 2020 16:57:20 GMT -6
Hello MM
Nice job on printing
I world like to let you know that I had bobbins printed as well and after winding copper wire on them they disintegrated ( lengthwise) Solution for me was to make bobbins from fibreglass boards ( PCB material)
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Post by Marathonman on Jul 16, 2020 21:15:55 GMT -6
I have a thread on how to make bobbins from resin. they are very strong and withstand a lot of punishment. i am thinking of printing with fiber X which is carbon fiber mixed in for a lot of strength which will allow me to print very thin to get the most magnetic bang for the buck. also if your 3D printer extruder temp was not high enough the layers will not bond thus self destruct when pressure applied. your fill rate might have been to low. the walls on the bobbin's i printed are solid printed at 215C and a bed temp of 60C. Regards, Marathonman
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Post by Marathonman on Aug 13, 2020 19:48:32 GMT -6
I was checking my clearances on the 3D printed bobbin and it seems i have a winner. am making wooden holders so the bobbin can slide on the winder to be wound. i have checked the bobbins by trying to rip them apart and that was a no can do so they will hold up just fine. the tough pla was printed at 215c with a bed temp of 60C and solid walls. they fused just great and will be a pleasure winding. i am thinking of grinding my cores so i can round the corners of the bobbins to ease the winding angle. once i test my present cores i have wound i will make that decision then. Regards, Marathonman
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Post by Deleted on Aug 14, 2020 18:13:36 GMT -6
Hi MM
I would like to warn you from potential problems . 3D printer does good job and under normal temperatures around 25 degrees C parts are reasonably strong . if you will increase temperature up to 55 Degrees C then part become playable and will deform accordingly tension or pressures of Winded copper wire.
In my tests all coils fall apart under thermal load testing , strongly advising to make bobbins form materials that will outlast higher temperatures. Regards Skyrob
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Post by Marathonman on Aug 16, 2020 19:06:56 GMT -6
Video was delayed as i had problems. what a time for a water pipe to bust. i will finish over the next few days and post. regards, Marathonman
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Post by Marathonman on Aug 19, 2020 17:05:34 GMT -6
Found time after successful print job of commutator ring brush holder to assemble. the idea i had for a double ring was scrapped for a more simplistic approach. even though i had two good prints i ended only needing one as you see in the pics. i guess i wasted 100 bucks on the aluminum rings being made as i upped the thickness to 3/16" on the PLA prints and is very strong i might add. this is why i do not mind taking my time as my impatience just cost me 100 bucks as i no longer need the Aluminum rings. 100 buck in beer gone down the tubes, i am hanging my head in shame. now all i need to do is trim one of the support shims on both sides to half the size which will put me in the middle of the commutator and i will be just fine. both sides will have wing nuts on them for ease of adjustments and the slots allow easy movement around the commutator. Regards, Marathonman
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Post by Marathonman on Aug 20, 2020 13:41:22 GMT -6
Cut myself with chainsaw for the first time in my life. right through my boot, sock and hit little toe. minor flesh wound and will live but it could of been worse but it was not. so since my foot hurts i thought i would take it easy and work on controller. installed slip ring brushes, the reason i installed two is for shaft balance but i might run just one. as you see from the pic below i still have the protective plastic on the aluminum sheet thus will remove when i am finished. Regards, Marathopnman
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Post by Marathonman on Aug 26, 2020 16:25:41 GMT -6
Been working on power supply for testing of the device. the prelim was very good by reducing the winding count on the primary transformer to half of what i had i attained good 12 and 100 volt outputs. the wire is still warming up a little though so i might have to up the awg. other then that i have had epoxy come in and i will be finishing the core of part G finally. full assembly is going to happen very soon. Regards, Marathonman
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