207 Photos - Jun 12, 2013
Photo: Photo: Photo: My grandfather is actually built these machines not so long ago. I mean he is 80+Photo: Photo: Photo: Photo: Photo: Photo: Photo: Bottom of the standPhoto: Figuring out the circuit and how to put it from paper into the real-working circuit.Photo: Never done anything like this.Photo: That analog multimeter was made in Russia. I think it's defective :-( Wanted to use it as analog amp meterPhoto: Figuring out the circuit.Photo: Figuring out the circuit layout to be it as clean as possible.Photo: Photo: Photo: Photo: The first one was the most difficult. To figure out how to hold , how this how that.Photo: The first one was the most difficult. To figure out how to hold , how this how that.Photo: The first one was the most difficult. To figure out how to hold , how this how that.Photo: The first one was the most difficult. To figure out how to hold , how this how that.Photo: Wett your contact points ahead . You don't want to heat up your devices too much. This way it's almost touch^release. Keep in mind copper wire absorbs and distribute heat like mad.Photo: Wett your contact points ahead . You don't want to heat up your devices too much. This way it's almost touch^release. Keep in mind copper wire absorbs and distribute heat like mad.Photo: Progress..Photo: 1N4007sPhoto: uqly ... this is version 1.0 ;)Photo: uqly ... this is version 1.0 ;)Photo: uqly ... this is version 1.0 ;)   ... but you learn slowly but surelyPhoto: lolPhoto: Kinda mesed up soldering. First timer ;) ... Second build was nicer and cleaner. You learn along the wayPhoto: Kinda mesed up soldering. First timer ;) ... Second build was nice and clean. You learn along the wayPhoto: Photo: I had to figure out how to do my own spool. So, this is what I figured out with available resources.Photo: I had to figure out how to do my own spool. So, this is what I figured out with available resources.Photo: I had to figure out how to do my own spool. So, this is what I figured out with available resources.Photo: I had to figure out how to do my own spool. So, this is what I figured out with available resources.Photo: Bore - d = 2cmPhoto: d=2cm ... dont know the english name of it .. help mePhoto: another angle ... ehmPhoto: fits good and tight  ,but that is not enoughPhoto: togetherPhoto: clearer picture , if you need ;)Photo: enough of this ....Photo: parts togetherPhoto: parts togetherPhoto: compare the size against my handPhoto: First time coil makingPhoto: street before the housePhoto: hookPhoto: measuring distancePhoto: is it 1turn per inch ? roughly ?Photo: Photo: not enough i think ... so we turned a little morePhoto: You would wonder how strong and heavy 40m long 8strand magnet wire is.Photo: Photo: Photo: Photo: When turning the wire with drill . Make it as straight as possible. Don't worry , the wire will not brake it's strong as f...Photo: not enoughPhoto: Done.
By the way ...

DNE0.70/1kg = SWG 22 (0.70mm)
DNE0.50/0.25kg  = SWG 25 (0.50mm)

It was 280m spool for the 0.70mm ...It should have been empty .. 7*40m=280m .... hmmmPhoto: Done.
By the way ...

DNE0.70/1kg = SWG 22 (0.70mm)
DNE0.50/0.25kg  = SWG 25 (0.50mm)

It was 280m spool for the 0.70mm ...It should have been empty .. 7*40m=280m .... hmmmPhoto: Done.
By the way ...

DNE0.70/1kg = SWG 22 (0.70mm)
DNE0.50/0.25kg  = SWG 25 (0.50mm)

It was 280m spool for the 0.70mm ...It should have been empty .. 7*40m=280m .... hmmmPhoto: Measuring the coil length with the core inPhoto: Measuring the coil length with the core inPhoto: Measuring the coil length with the core in. Need to strip some of those rodsPhoto: Photo: Notice the glue ... looks like a T-Fighter from StarWars , isn't it ? :DPhoto: Notice the gluePhoto: Notice the glue , T-Fighter ;DPhoto: This was the most difficult to do. Without lathe it's different task :)  First attempt failed. The spool top and the core loosened ... because of the strong friction against the wooden wall ....Photo: Photo: to maintain tension on the wire ... I was tensing the wire with my hand anyway.Photo: raw material ;)
unwinder ... or whatPhoto: still the bad approachPhoto: Photo: Photo: Photo: Notice the "ring" between the wooden wall and the spool ... now it's perfectPhoto: perfect ... holding the spool nice and tightPhoto: perfect ... holding the spool nice and tightPhoto: Done !!!!!!!!! WhooaaaahPhoto: Photo: The coil is done. And I am relieved ;)Photo: Photo: put the thing into the thingPhoto: put the thing into the thingPhoto: a quick stand for it ... hurrying to hook the whole thing upPhoto: closer look at the CoilPhoto: not a sharp one ... butPhoto: Photo: Glue the rods and notice the transparent glue on the wire at the right sidePhoto: the top of the coil tilted a bit , but I don't care it is acceptable. It's a millimeter or two. Later I adjusted by hand ... it's ok nowPhoto: another lookPhoto: closer lookPhoto: glue to supporPhoto: machined reduction for the bike wheelPhoto: Photo: Photo: Photo: Photo: ok ok I know it's an aluminium wheel. There wasn't any steel one available. So I bought this one. Steel wheel will be used in my second SSG which I found in the scrapyard.Photo: Photo: Photo: Photo: Photo: Photo: NEVER UNDERESTIMATE A FLYING MAGNET :D I learned it fast. Believe me , you will too. It hit the coil then it took the whole circuit with it. I experienced it :DPhoto: NEVER UNDERESTIMATE A FLYING MAGNET :D I learned it fast. Believe me , you will too. It hit the coil then it took the whole circuit with it. I experienced it :DPhoto: Working bench
quick setup ... wanted it to see it running :DPhoto: quick setup ... wanted it to see it running :DPhoto: After the flying magnet incident I went to sleep crying :D  and the next day I made it acceptable for the job ;D Some magnets were still clicking hence the wheel is round and the magnet is straight and .... think man thinkPhoto: Photo: Photo: 1.5k pot ...  for 470ohm base ... like ~600ohm pot is enoughPhoto: DIY knob ;DPhoto: Photo: glueing the thing togetherPhoto: glueing the think togetherPhoto: Glue one side of the wheel first ... then let it sit for day  then do the other side.Photo: transparent , strong-hold , long-dry , universal glue ... still holding strongPhoto: the nut was machined down to round shape and was inserted into the reductionPhoto: the nut was machined down to round shape and was inserted into the reductionPhoto: the nut was machined down to round shape and was inserted into the reductionPhoto: I knooooow IT supposed to be non-magnetic material. Notice the steel wheel in the background ;) for the second SSGPhoto: Photo: measuring and stuffPhoto: Photo: Photo: lovely ... notice the circuit ... dissasembled at least 4-5 times  so,,, ... I was stupid until I figured out how the whole thing is working.Photo: Photo: Photo: Photo: circuit revision 2.0Photo: circuit revision 2.0Photo: diodes first - 1N4007Photo: diodes donePhoto: diodes donePhoto: diodes done .. nice and clean jointsPhoto: meh .. enough of this ...Photo: Once I had the diodes ... 
Soldered the NE-2 then the resistor ... and repeated the procedure

I decided to do this layout to be it as much understandable as possiblePhoto: Once I had the diodes ... 
Soldered the NE-2 then the resistor ... and repeated the procedure

You like it ? :P

I decided to do this layout to be it as much understandable as possiblePhoto: another angle

I decided to do this layout to be it as much understandable as possiblePhoto: I decided to do this layout to be it as much understandable as possiblePhoto: Output ... I want thicker gauge wire ! But this is what I have nowPhoto: For input should be enough ... But it's not finalPhoto: Messing around with small batteries.Photo: base frame revision 1.1 ... made it wider to fit the circuit inside . I want to protect the circuit with a plexi window in front of it.Photo: base frame revision 1.1 ... made it wider to fit the circuit inside . I want to protect the circuit with a plexi window in front of it.Photo: side view .. coil stand is still demo :D

I know i know ... steel is problematic
 ... will be wooden don't worry .. Besides it is running really nice.Photo: Photo: Photo: It charges these small ones quite fast. But at 1amp input it discharges fast also. Running it only at ~750mA for better discharge rate.Photo: The whole thing is able to run from ~250mA minimum inputPhoto: Photo: 1 input batterry - 3 output batteriesPhoto: This will take  two or three days to charge. 12.93V after ~24hours from ~12.5V. The BOSCH S4 is brand new 85Ah batteryPhoto: Coil stand is done. You better don't want to know the distance between the magnets and the clamp :-PPhoto: The coil with the stand vibrates ... in order to calm it down and sit it nice and strong ... I used those 2 clamps temporarily. I will use 2 or 4 bolts to tighten the stand.Photo: I mess around with these ones and some more...Photo: Photo: Photo: Photo: Photo: Second SSG - bigger wheel , steel wheel , less magnetsPhoto: Second SSG - bigger wheel , steel wheel , less magnets = more efficient I would say , need more dataPhoto: Second SSG - bigger wheel , steel wheel , less magnetsPhoto: 300mm aluminium fanPhoto: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: Photo: my work space right nowPhoto: Photo: Photo: