An Alternator Powered Electric Bicycle Gives Rotor Magnetic Field Insight

January 24, 2021 by Jenny List 63 Comments

For anyone involved in the construction of small electric vehicles it has become a matter of great interest that a cheap high-power electric motor can be made from a humble car alternator. It’s a conversion made possible by the advent of affordable three-phase motor controllers, and it’s well showcased by [austiwawa]’s electric bicycle build video (embedded below).

The bike itself is a straightforward conversion in which the motor powers the rear wheel via an extra sprocket. He tried a centrifugal clutch with limited success, but removed it for the final version. Where the interest lies in this build is in his examination of Hall effect sensor placement.

Most alternator conversions work without sensors, though for better control it’s worth adding these magnetic sensors to allow the controller to more directly sense the rotation. He initially placed them at the top of the stator coils and found them to be ineffectual, with the big discovery coming when he looked at the rotor. The electromagnet in the rotor on a car alternator has triangular poles with the field concentrated in the centre of the stator, thus a move of the sensors to half way down the stator solved the problem. Something to note, for anyone converting an alternator.

Should you wish to give it a try, a year ago we published a primer on turning car parts into motors.

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DIY Automated Roller Blinds

December 5, 2020 by Rich Hawkes 11 Comments

Controlling blinds using off the shelf solutions can be expensive – more so if you have multiple blinds you want to control. [HumanSkunk87] felt the cost was too high, so they designed a controller to automatically open and close the blinds.

The main part of this build is a motor and a ball chain gear – a wheel that captures the balls of a ball chain so that the chain can be pulled. The wheel was designed using Fusion3D and then printed out. The motor requires enough power to pull the chain — [HumanSkunk87] figures it needs to be able to pull about 2.5kg in order to raise the blind. After giving up on stepper motors, a DC motor with a worm gear was found to have enough torque to work. A WEMOS D1 Mini controls the motor controller that drives the ball chain wheel. Two micro switches tell the WEMOS when to stop at the bottom and top of the window.

The WEMOS is programmed using ESPHome and it connects to [HumanSkunk87]’s HomeAssistant to complete the automation. Check out the descriptions in the link for the parts and the code used to run everything. There are many other creative ways to open your blinds, It’s even possible to automate curtains instead of blinds.

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Beer Pong Difficulty Level: 10

November 21, 2020 by Bryan Cockfield 2 Comments

Beer pong is a fun enough game for those of a certain age, but one thing that it lacks is a way of cranking up the difficulty setting independent of the amount of beer one has consumed. At least, that was the idea [Ty] had when he came up with this automated beer pong table which allows the players to increase the challenge of this game by sliding the cups around the top of the table.

The build uses a belt-driven platform under a clear cover with a set of magnets attached. Each of the cups on the table has a corresponding magnet, which allows them to slide fairly easily back and forth on the table. The contraption is controlled by an Arudino Nano with a small screen and dial that allows the players to select a difficulty level from 1 to 10. The difficulty levels increase the speed that the cups oscillate on the table, which certainly adds another layer of complexity to this already challenging game.

While we hope to eventually see a beer pong table that can automatically arrange the cups as the game is played, we do appreciate the effort to make an already difficult game even more difficult. Of course, if you have problems with the difficulty level you might want to pick up a PongMate CyberCannon Mark III to help with those clutch beer pong shots.

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3D Printed Electric Motor Wants To Take Flight

November 18, 2020 by Al Williams 49 Comments

Airplanes and spacecraft have a big problem. The more engine or fuel you have, the more engine and fuel you need. That’s why aircraft use techniques to have lightweight structural members and do everything they can to minimize weight. A lighter craft can go further and carry more payload or supercargo. Electric motors are very attractive for aircraft, but they suffer from having less efficiency per kilogram than competing technologies. H3X thinks they can change that with their HPDM-250 integrated motor and inverter.

Although the 15 kg motor is still in testing, the claimed specifications are impressive: a peak power of 250 kW for 30 seconds and continuous torque of 95 Nm and 200 kW sustained. The company claims 96.7% efficiency. The claims are for the motor running at 20,000 RPM, so you’d need to add the weight of a gearbox for practical applications, but the company says this adds a mere 3 kg to the overall weight.

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World’s Smallest Version Of World’s Fastest Bumper Car

October 12, 2020 by Kristina Panos 6 Comments

A few years ago, YouTubing madman [Colin Furze] took an old bumper car and made a 600-horsepower beast of a go-kart that managed to clock 100MPH with a headwind. This isn’t that. It’s a miniaturized, remote-control homage to [Colin]’s go-kart that is equally awesome.

[Forsyth Creations] started by CAD-modeling the chassis right on top of a still from the video. The entire body is 3D-printed in four large pieces, which took several days because each piece took around 24 hours. Inside the car there’s an Arduino brain driving a motor in the back and a servo in the front. This bad boy runs on a couple of rechargeable battery packs and can be controlled with either a Wii balance board or a PS2 controller. This thing really moves, although it doesn’t quite reach 100MPH. Watch it zoom around in the video after the break.

Got a Segway lying around that just doesn’t do it for you anymore? You could always turn it into a go-kart. Never had a Segway to begin with? Just roll your own.

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This Tabletop Lighthouse Will Get Your Attention

October 4, 2020 by Kristina Panos 7 Comments

If you wear headphones around the house with any regularity, you’re probably missing out on a lot of audio cues like knocks at the door, people calling your name, or maybe even the smoke alarm. What if you had a visual indicator of sound that was smart enough to point it out for you?

That is the point of [Jake Ammons’] attention-getting lighthouse, designed and built in two weeks’ time for Architectural Robotics class. It detects ambient noise and responds to it by focusing light in the direction of the sound and changing the color of the light to a significant shade to indicate different events. Up inside the lighthouse is a Teensy 4.0 to read in the sound and spin a motor in response.

[Jake]’s original directive was to make something sound-reactive, and then to turn it into an assistive device. In the future [Jake] would like to add more microphones to do sound localization. We love how sleek and professional this looks — just goes to show you what the right t-shirt stretched over 3D prints can do. Check out the demo after the break.

Seaside lighthouses once used gas lights giant Fresnel lenses, but now they use LEDs. A company in Florida is using CNC machines to crank out acrylic Fresnels.

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Electric Volkspod Takes You On An Eco-friendly Beetle Cruise

October 3, 2020 by Sven Gregori 9 Comments

The Volkswagen Beetle is a true automobile icon, and while it may not be the fastest or most breathtaking looking car ever built, its unmistakable shape with those elegant curvy fenders and bulgy lights holds a special place in many people’s hearts. And then it inspires them to build minibikes from those same parts.

[Brent Walter] is well know as an originator of the hobby, starting a little while ago with his Volkspod. Inspired by [Brent’s] work, [Jonah Mikesell] decided to give it his own try, but unlike the original design that uses an actual minibike under the hood, he built an electric version of it, and painstakingly documented every step along the way.

The idea of the Volkspod is to take the Beetle’s two front fenders, weld them together to one symmetric body, and turn it into a small motorcycle. [Jonah]’s version does all that, but instead of taking a whole minibike as core of the project, he only uses a minibike frame and substitutes the engine with a 2000 Watt e-bike motor along with an e-bike battery pack. Fitting the frame within the dimensions of the fender construct required some extra welding work, but in the end, it all came nicely together, and with its red paint job, it kinda looks like something from a vintage post-apocalyptic sci-fi cross-genre movie. Watch him taking it for a spin in the video after the break.

Unfortunately, neither the original Volkspod nor this one has the roaring engine sound of an actual Beetle — which is akin to what the wings of a real-life beetle of similar size would probably sound like. But well, it’s always an option to fake that. And if [Jonah] ever feels the urge of a bigger engine, maybe a washing machine can help.

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