Building the sickest ® VAWT ever. Brilliant minds unite please!!

[brandnewb]

this is getting ridiculous.

I never informed the FDF about my speed requirements so an S52 chain is possibly not fit for purpose.

Sedis general catalogue – note on page “Roller chain ISO 487 S type chains” says
“It is preferable that the linear speed of the chain is less than 0,5 m/s.” (≈ 30 m min-¹)

https://www.sedis.com/fichiers/uploads/sedis-catalogue-principal-products.pdf

To get the PMA up to around 300 RPM the motor needs to rotate at around 150% of it's rated RPM. The VFD (that performs remarkably well even though clearly the wrong choice) can do it but only with 230 V as source. Not the 400 V the motor is expecting.

I have this radiation warning for a reason but just going in with wrong chains is also not advisable.

 

[brandnewb]

it is confirmed. well at least by me via assumption based on assumption.

Deep down I have always feared this moment.

I have to give up on PLA for the motor sprocket in this test setup.

It is not about strength. We have already seen how to work around that problem.

It is the overheating problem that will turn the sprocket to golly not long after we start giving it hell.

I am aborting this current avenue. Should I try it I again have to report hard failures. Now although they might be worthwhile for disaster tourism. I really need to get this show on the road

PS.for the PMA sprocket the jury is still out regarding PLA.

 

[brandnewb]

haha I actually meant soft failures that would be needed to be reported. As PLA will turn to gelly at that stress levels

 

[brandnewb]

well you know this lady yes?

the one that can sing now do you?

Still does not ring a bell? I mean the fat lady that is not yet singing.

Ahh now you are catching on finally.

Well it is not over for the timing belt just yet. Not as long this lady has not begun singing yet.



I aborted this print because of the tiny gaps that I could poke a nozzle clearing needle through.

But next print will be more solid.

Why so thin I hear one wonder.

Well that is because then it does not take ages to print a new one if I need to fine tune. I just hook it up to the base that I need to design still.

Also things are going to be tight this time around. I will give the 32mm timing belt but 32.5mm space and no way to escape the pulley.

I am thinking things will become BLISS if done like that

 

[brandnewb]

here. much better.

Please remind me next time to babysit a print when in early stage.



sure we can fine tune the flow to make each layer smoother but I think you already know by now how much I care

 

[brandnewb]

hahahha

I see myself and my wife here



an object hold tight (by an although seemingly small yet a great power wielding force) trying to escape at every turn.

hahahahahah

I think this might work. I do not expect any wandering/creeping of the belt any longer. If all goes well that is.

I am working on the the prints to secure the pulley to the PMA as we speak.

The pulley for the motor is already installed on the motor shaft.

the ramps are segmented because I have but so much print real estate. so I had to cut things up

But then again. making things modular does allow for less painful failed prints as it is only one part that we have to try again rather than the whole thing.

 

[brandnewb]

so this is what I am planning/printing. If one already sees how this can never work then please do not be shy..

 

[brandnewb]

I wonder if I am printing too fast and that the infill overlap is too much of a good thing.

But unless someone stops me I am going on.



maybe even the fastner is not thick enough but we will see,. easy to print better ones since things are modular

 

[justgary]

It could just be time to clean the nozzle.

 

[brandnewb]

look, I realize it is off putting to involve AI.

But I think that if we do not explore all avenues then we are not doing projects properly.

Just because DASS is ...

well you know..

A dumb a$$

That does not mean that if you can hold it real tight and steer it into a direction you need to, it is not a benefit.

It is the same with code developers. The people that can make good use of AI are the people that actually do not need it to begin with

I see that myself in my own projects I have on the side after having retired from the game.

It is even called the AI paradox of some kind if I read the article on the register correctly or where ever I read the first time the term was coined.

Now regurgitating code from github is far more easy for AI, especially as I can directly spot where I need to step in and correct, than getting this new AI technology to actually help build a turbine.

It is still leaps and bounds too much for AI. Or at least the models I have tried and the ways I have used them.

Anyway this is a long introduction to that DASS thinks we are good to go with the PMA pulley. All factors are considerd and even if we get up to 2KW then the pulley should still keep smiling.

Now we can blame DASS if things go wrong

hahha
no of course not.

I am still the one in charge here!!

 

[brandnewb]

ohh shit. here we go again.

This time I am not being asked upstairs but summoned.

no no no. I need to escape

hahahah

 

[svetz]

I wonder if I am printing too fast and that the infill overlap is too much of a good thing.

Maybe run the Calibration tests on the filament to ensure the correct temperature and flow?

 

[brandnewb]

btw gang. if I am ever found hung by the neck. then it was not my family. There are powers out there that like to keep being able to misinform.

 

[brandnewb]

captains log. stardate --too long

The previous test was a great idea. But the fasteners turned out to be either too close or too far.


Hence yet another test case.

We will see what gets us to full power transmission. A Clear (transparent PLA) print of the PMA pulley. Yet hollow and filled with UV resin.

And Gary was correct. No need for high power UV emitters Just Sun and all is Bliss.

But now I fear it might be too brittle in where when I start securing it it might shatter.

This is why I love PLA filament (this edit was done to keep the CIA off my back and mistake me for some kind of activist)

 

[brandnewb]

please bear witness on how much of a dumbas$ I really am.



that was en exaggerated representation of how the coils were misaligned.

That means

They have never been properly

this is where we should end up.



And look at that tiny spacer there on the right side of the coil. I bet you can imagine what the point of that is yes?

pun obviously intended

 

[brandnewb]

just so one remembers I am not one to back down easily.

I will only admit defeat when I see no more path forward.

Now please do not let my wife read this because then I'd be in for another spanking I tell ya

 

[brandnewb]

ok i am done with this.....


what we need is a VFD that operates similar to the one we have now. But then 3 phase 380V.

And I found one. It is the exact same as we have now, but then level UP..

I hope this will mean we do not blow up yet another expensive VFD

 

[brandnewb]

what I really no longer can ignore is the fact that I need more power of expression.

I never will become a great writer and my stories with photos alone will never cut it and only take up space on this server.

@upnorthandpersonal I really think it is time you and I spend some time on this self hosted peertube thingy.

Otherwise it feels like I talk and everyone can see my mental image. But this is not how things work

Is that a plan?

 

[brandnewb]

after a painful day full of emotions getting all the furniture out of my moms apartment,

I found yet again a good way to express what it is I am going through.

look how slow the leave is moving this time around. as slow as I am.

And then later things pick up speed.

 

[upnorthandpersonal]

@upnorthandpersonal I really think it is time you and I spend some time on this self hosted peertube thingy.

Finding time is the hard part... I have so many things on my ToDo list, it's insane.

 

[brandnewb]

understood./ I will see if there is a way for me to test the embed ability of peertube then out there in the wild and see if you can implement it here.

 

[brandnewb]

Ok @mikefitz

Given you are a follower that actually is for real with a long track record here. I am going to keep going.

You must, like me, be interested in where does this lead yes?

Ok then I post again without new results just for the sake of keeping the soul alive.

I now have a harnass for the coils. It will prevent the magnet hitting the coils and chiping away from them.
This can only happen for not too long before the coil is no longer a coil do to short cuircuits.


and yes from this angle one might thing it is still not algined. But but but.


I told one


Now please do not expect earth shattering improvements.

I am looking at roughly 20% better results. Nothing to sneeze at sure but also still not confirmed so we need to hold on to our buttucks once more.

 

[brandnewb]

captains log. stardate --too long

The previous test was a great idea. But the fasteners turned out to be either too close or too far.


Hence yet another test case.

View attachment 304284We will see what gets us to full power transmission. A Clear (transparent PLA) print of the PMA pulley. Yet hollow and filled with UV resin.

And Gary was correct. No need for high power UV emitters Just Sun and all is Bliss.

But now I fear it might be too brittle in where when I start securing it it might shatter.

This is why I love PLA filament (this edit was done to keep the CIA off my back and mistake me for some kind of activist)

It is confirmed!!


It is not too brittle.

It can be squeezed quite a bit.

This is not to say that it is soft. NOT at all.

It means we can apply rather large loads on it before it fails. It can even help with the pulley not being perfectly centered (I am talking below mm discrepancies here). Anything larger and things will get torn off when things start rotating for real.

 

[brandnewb]

Ok I now believe I was right in where adding more cells will increase the potential for the motor (how ever badly driven by the VFD) to reach full potential.

Cell Count	SOC	Charge (VDC)	Current (A)	Power (W)	L2L VAC (RMS)	Frequency (Hz)	RPM	Comment
1	3.15	3.19	6.99	22.2981	4.689	46.92	58.65	only a single magnet disk because with one cell the motor /VFD combo was not able to get up to speed when there are 2 magnet disks
1	3.15	3.21	11.3	36.3	4.776	71.24	89.05	''
1	3.15	3.23	14	45.4	4.847	88.98	111.225	''
2	6.09	6.11	4.4	26.8	7.367	39.99	49.9875	I am not feeling ready yet to add the second mag disk again.
2	6.09	6.12	8.19	50.1	7.639	61.83	77.2875	''
2	6.09	6.13	12.4	76.3	7.733	84.11	105.1375	''
4	13.1	13.2	7.65	101	14.62	75.8	94.75	''
4	13.1	13.2	10.4	138	14.82	96.26	120.325	''
8	26.3	26.4	7.18	190	26.66	100.5	125.625	before I continue I want to try again adding the second disk

I will add 8 cells with a second disk first and if this confirms my hunch that that is already enough cells to allow for the motor to push the PMA then I will also add 16 and 32 cells but only having 2 disks.

what frustrates me still is that I still do not know if this is a good way to proceed or not.

I will do the known load tests like @justgary suggested but that is just to leave no one off board.

@upnorthandpersonal please if you can find time, do you have an idea on how to gather practical field performance data on a PMA?

 

[upnorthandpersonal]

do you have an idea on how to gather practical field performance data on a PMA?

First you have to clarify what exactly you're interested in measuring. Two aspects that come to mind, electrically, that could be of interest:

- Output voltage and current under varying loads
- Power efficiency across RPM ranges

At least those two are rather easy to measure. You can then graph them to get an idea where your optimal working point would be located.

The table you have is a good start - now you just need a few more data points. You're then basically doing benchmark extrapolation: take some measurements at 10%, 30% and 60% (for example) and then extrapolate the curve.

If you're looking purely at the magnetic aspect, you can measure magnetic flux density, inductance, back-EMF, etc., at a few rotor speeds or loads and extrapolate performance over the full range.