- Disk generator than can be mainly 3D printed
- One stator disk containing 12 manually or automatic wound coils
- Coils are cast with epoxy
- Two rotor discs, each containing 20 neodymium magnets
- Each rotor disc is supported with a ball bearing
The Nerdiskerator is a design for a disk generator that is mostly made from 3D printed parts. Additionally it is a component for "WinDIY" the 3D printed wind turbine (Infos here: https://hackaday.io/project/172328-windiy-hawt-wind-turbine).
But that doesn't mean that the Nerdiskerator can only be driven with a wind turbine. For the future I am also planning to develop a water turbine, which can then also generate energy from hydropower. :)
The design of the Nerdiskerator is mostly finished. A first protoype is already built. Actually I'm planning to build a new version that should include all final improvements. :)
Videos of several design steps:
A video of the winding of the coils via the "WinDIYingThing" (an automatic coil winding machine that I used to manufacture the coils properly):
- Build second version of actual design: pending
- Test second version in test stand: pending
- Design housing for generator
- Design housing for load resistor heat sink
- Design flow for control-software
- Design PCB for control circuit
- Design and build teststand: Done: https://hackaday.io/project/172445/log/180101-test-stand-for-the-nerdiskerator and https://hackaday.io/project/172445/log/180251-test-stand-gets-pwm-speed-controler-update
- Print/organize parts for second build: Done
The Nerdiskerator was initially a coincidental project that arose out of curiosity. It all started with getting cheap neodymium magnets at the flea market. As a technically easily enthusiastic person, I struck directly when buying without actually knowing what I could actually use the magnets for.
I thought its a shame to simply use the magnets as fridge magnets. I like to build practical things and also wanted to do something useful with the magnets.
Of course, the first technically useful use that came to mind was, to generate energy.
When I thought about that, it came to my mind that I knew theoretically how a generator works and how it is built. But now when it came to the practical construction, however, I was a bit lost at first. During my research, I also noticed that there were already a few designs for a disk generator made from the 3D printer. Unfortunately, no design would have matched my magnets.
I think most people who built disk generators made it smarter. They first thought about how the disk generator should be constructed and THEN bought the right magnets. For me it was the other way around. I had magnets but no suitable generator for it. So I gradually started designing a disk generator to match the magnets I already had. :)
Needed Sensors and actuators for the "Nerdiskerator-controller":
- Speed measurement: via Hall sensor and detection of voltage zero crossing/frequency
- Voltage and current of the generator after rectification
- Temperature of the heatsink of the load resistors
- Measurement of the position of the brake cylinder using a sliding resistance
- Current consumption of the stepper motors (brake and pitch adjustment) to detect any blockage
- 2x limit switches to recognize when the brake cylinders are completely "open"
- RTC (for recording of log files)
- Accelerometer to detect abnormal vibrations
- Voltage and current measurement of the buffer battery
- Compass module to recognize cardinal direction
- MOSFET for load restors
- 3x NTCs between the coils of two phases each
- Extra MOSFET to be...