It's been a long (LONG!) time since I did a big, fun project. So my my solar installation is taking that space in my heart for the last 9 months and foreseeable future. I've done some small projects, but...
I built a headlight for my road bicycle - not your average headlight, though. I built from scratch a 3-phase alternator. It's encased within the hub of a kid's scooter wheel, rides the top of the front tire and attaches to the fork crown with a bracket that contains the rectifier and protection circuits. I get about 60W out of it at 30 MPH, and need up to 30W for the LEDs. It's bright as daylight starting around 15 MPH.
Rectified DC is fed into the control box and powers three 4-die Cree MC-E LEDs (about 30W and 15,000 lumens of raw LEDs). The brightness of the LEDs is adjusted in proportion to the alternator output. This is not as simple as with a light bulb that just gets brighter with more power. It uses an Arduino chip to control the LED brightness and manage a few other features:
- Temperature monitoring on the LEDs.
- Current monitoring on the alternator (max 3A).
- Internal Li-Ion cell to allow for a low light setting when stopped (about 15 minutes).
- Current monitoring on the internal "battery backup" system.
- Management of the internal battery charger.
- Display of the alternator output, battery charge state and charger mode via three RGB LEDs on the case.
- Audible alarm for all conditions of concern.
- Tail light that is GUARANTEED to be visible for many hundreds of yards, which also has a battery back inside.
My YT channel has some test and intro vids in a playlist.
https://youtube.com/playlist?list=PLQFOjYqw8mbTfu0dU3LdB-BMzvEuwHbta&si=Jm2bVR3BZHcA6Kjx
And here are a "few" pics of the build:
3D rendering in Google Sketchup
Wound each coil with 144 wraps of 28AWG magnet wire.
Seeing how the magnets fit in the wheel.
Potted and extracted from the mold
Testing and adjusting the clearance between magnets and coils. Just 1/16th inch difference resulted in twice/half the alternator output, so I squished it as close as I could get without rubbing.
Nice output!!
The alternator - tested and optimized. Now to mount it.
Mapping out the alternator's performance at every speed up to 30 MPH.
Data makes pretty pictures. And the over-voltage clamp circuit works as hoped!
Building the headlight
Status indicators
Building the tail light
Started in 2008. Completed in 2016. It's been mounted to my road bike ever since. And I LOVE doing night rides, especially when it's in the low 40s(F) outside. It's peaceful and quiet.