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Home Power Plant Welding Unit 1987

Home Power Plant Welding Unit 1987

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Published by the_pacifist
Using automobile alternator for power
Using automobile alternator for power

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Published by: the_pacifist on Oct 29, 2011
Copyright:Attribution Non-commercial

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10/29/2011

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HtJlIII
FtJ
BUII-DAHIGH
IftJl.
FA
GIl
HtJMIlPtJlIIIllRPfANFANDIIIIIlI-DINGUNIF
Using
LowCostUsedCarParts
and
NaturalEnergyDriveSystems
Publllhldby:TAENDLINEPUBLISHINGCOMPANY(ADIvisionofTrendllneIntemetlonalPly.Ltd.)G.P.O.Box1889,Sydney,2001.Australia.
eCopyright1983.TrendlineInternationalPty.Ltd.RevisedandupdatedEdition1985ISBN0
-
864370008.
Reproductionprohibitedbyanymethodwithoutpriorpermissioninwritingfromthepublishers.
This
manualiscompiledfrom
a
specialprojectheadedby].T.AllowynandcommissionedbyTrendline
InternationalPry.Ltd.Theinformationcontainedhereinisbelievedto
beaccurate,bur
is
sold
asinformationonlyandnoliability
is
accepted
by
eitherthepublishersorresearchanalysts.
WARNING
Theinformationinthismanualwillenableyoutoproducehighvoltagefromcaralternatorsandcarbatteries.
HIGHVOLTAGESCANCAUSEINSTANTDEATH.Alwaysinsulateconnections.andwhenproducingover60
volts.clearlylabel
-
"DANGER
-
HIGH
VOLTAGE".
1
 
CONTENTS
.Introduction."810COII8tructlonendOperailngDetail..Alternatore
-
Output,
Wiring
andMoclltlcatlons
-Howto
ConnectAlternatorsinParallel
-
HowtoConnectforFastChargingofBatteries
-
HowtoConnectforWelding
-
HowtoConnectforOperating24Ovo1tDrills,Lights,PowerToolsetc.
.DrIveLIneOptIons
-
LawnMoweror
Molar
CycleEngine
-
RearWheelofCar-V-BeltDriveoffCarMolar
-
TwinAlternatorDriveoffCarMotor
.Drive
Speed,
Voltage
andPo"".r
Strength
-
HowtoCalculateAlternatorSpeed
-
HowtoCalculalePulleySIZ88forSpecificAIt8m8IarSpeed
-
HowtoCalculatePowerStrength;AmVallsandWatts.
.BatteryCalculatlOl'I8l1ftdHook"'"enee
-
HowtoConneetIn111gbVI"""
-
HowtoConnectInPar8II8IforHIghAmpC8pecfty
-
HowtoConnectInCombinedPar811e11SerlesforIncreasedAmpCapacityandHigherVoIt8g8s
.BatteryFacts
-FactorswhichDetermineBatteryPower
-
BatteryCharging
-
CausesofBatteryFailure
-
ChemicalFormulastoExtendBetteryLife
-
HowandWheretoGet
Good
UsedBelteries
.
Inverters
-
RotaryInverters
-
SolidStateInverters
-
TipsonBuyingInverters
.L01NVoltage
Appliance.andTools
-
Fridges,Radios,CoiourTelevisionetc
-
HeavyDutyFencingTool
-
10mmWorkshopDrill
-
CompactBatteryOperatedWelder
-
UsinganOldCarGeneratorasanElectricMotor
-
UsinganOldCarStarterMotortorHIghPow8r,ftIgItTorqueApplications
.
HornePo1NerPlentOptIons
and
Combinations
.
AlternativeEnergyDriveSystems
-
DirectFlowWaterPowar
-
RegulatedDirectFlowWaterPower
-
WaterPoweredOn-siteGravityUnit
-
WaterPuweredRemoteLocationGravityUnit
-
WindPoweredConventionalPropellerTypeWindmill
-
WindChutePowerTurbine
eWeldtng
Capabilitle.
-
ArcWelding
-
FusionWelding
-
SpotWelding
-
Brazing
-
Heating
-
Soldering
-
Cutting
-
WheretoBuy'CarbonArcRods
.Conclusion
2
 
INTRODUCTION
Theordinarycaralternatorcanbeeasilymodifiedandusedasaconvenientmobilepowerunit.Itcanbeeithermountedonacompactplatformanddrivenbyasmallpetrolmotor,windmill,waterpower,etc.,ordrivenbyyourcarmotorattherearwheel,etc.Thispowerunithasbeendesignedwithenormousversatilityrangingfromsimpleapplicationssuchaslightingandheatingthroughtobrazingandwelding.Theoverallaimhasbeentoconstructanalternativepowersourcefromlowcostcomponentsandusedcarparts.Theemphasisisonusedcarparts,e.g.:usedcarbatteriesinsteadoftheveryexpensive,butbettersuitedheavyplatepowerplantbatteries.ThereasonfortheemphasisOflusedcarpartsismainlytheirlowcostandeaseofavailabilityanywhereinAustralia.Asanexampleofcosts,second-handalternatorsarereadilyavailablearoundSydneyfor$15-$20eachingoodworkingorder(oftenadvertisedintheweekly
TradingPost).
PresumablytheyareeasilyavailableatsimilarpricesinotherStatesaroundAustralia.Asanexampleofthecapabilitiesofthisunit,youcanarcweldusingweldingrodsup
to
12gauge(2.5mm),solder,braze,brazeweld,fusionweld,spotweld,cutsteel,andheatsteeltonearmeltingpointforshapingandbending.
Note:
Thisisalldoneby
electricity,
directlyfromyourpowerunit.Theunitissupplyingpowerdirect--itis
notevennecessarytobuyawelder.
Formostpeople,readingthesetypesofclaimsinouradvertisementsisunbelievableandforsomeitistotallyunacceptable.Thethoughtofcreatingintense
heatandflame
capableoffusion(oxytype)weldingandheatingsteeltonearmeltingpointishardenoughtobelieveevenifusingthebestofelectricweldingequipment...buttodoallthesethingsandmore
withoutawelder
andusinganoldcaralternatorappearstobebeyondtherealmsofpossibility.Inthefollowingpagesyouwillseethefactsandrealizethatouradvertisingclaimsarenotanoverstatementbutratheradeliberate
understatement
offact.
BASICCONSTRUCT1ONandOPERATINGDETAILS
Themodificationstothealternatorarequitesimpleandstraightforward.It
doesnot
requireanycomplicated
rebuilding
-
allmodificationsaretoexternalwiringconnectionsonly.
Basicallytheconceptisverysimple:by-passtheregulatorandrt!naconstant12voltsdirectlyintothefieldwindings(rotor)ofthealternator.Thisenergisesastrongmagneticfieldinthealternator,andthefasteritisdriventhehigherthevoJtage-upto250volts.Normallytheregulatorcontrolstherotorcurrenttokeepthealternatoroutputatitsconstant12volts(13.8voltsmaximum).Theregulatorcontrolstheinputtotherotorwithintherangeofzeroto12voltswhichreducesthemagneticfieldtherebycontrollingtheactualvoltageandamperageoutputfromthealternator.Byeliminatingtheregulatorcompletelyandconnectingthebatterydirecttothefieldwindings,thentheoutputisdirectlyrelatedtothespeedofthealternatorinsteadofbeingcontrolledbytheincomingcurrent.Tosetupyourportablepowerunit,youwillneedanalternatorwhichhasaseparateregulator(notaninbuiltregulator).Theseparateregulatorset-upwasstandardequipmentonmostmodelspriorto1980,soitwillnotpresentanyprobleminbuyingthisparticulartype.Youwillalsoneeda12voltcarormotorbikebatterytosupplycurrenttotherotor,andanoldlawnmowermotororpreferablyamotorbikemotortodrivethealternator.Thatisbasicallyallthatisrequiredasfarasmajorcomponentsandmodificationsgo.Alternatorsarecapableofspinningatveryhighspeedsbecauseoftheirsolidintegraltypeofconstruction,whereastheoldgeneratorstendtoexplodeorflytopiecesathighspeed.Thisismainlybecauseingeneratorstheindividualbrasssegmentsofthecommutatorhadtobeelectricallyinsulatedfromeachotherandthereforecouldnotbefabric-atedfromasingleblockofmetal.Athighspeedthecentrifugalforcecausedthemtoflyout.Thisproblemdoesnotexistwithalternators,andtheyarequitesafeatveryhighRPM;infactdoubleenginespeedisnormal,andtheyare
quitesafeupto14000
-
15000RPM.Whenyourpowerplantisinoperationthepowerdrainonthisbatteryisonlyabout3-4amps,atthemost,so,youcanruntheunitforquitealongtimebeforeyouneedtorechargethebattery.Forexample,usingafullycharged100amp/hrbatteryatadrainof4ampsyoucouldruntheunitforcloseon25hoursbeforerecharging.Inactualfact,yourpowerunithasafastchargecapability,soyoucanvirtuallyrechargeatruckloadofcarbatter-iesinthat25hoursifyouwantedto,sothissmallpowerconsumptionisneveraproblem.Somepeopleprefertouseth~irexistingalternatorset-uponthecar.ThisisquiteOK,becausetherearenoactualmodificationstothealternator.Theonlymodificationrequiredisinthewiringconnections,thatis,inby-passingtheregulatoretc.Whenyouhavefinishedusingthepowerunit(alternator),simplyswitchitbackthroughtonormaloperationandletthebatteryrechargeitselfinthenormalmannerasyoudrivealong..
3

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