90+ Amps! Home Made Honda GX160 12v DC Generator Version 2 - Upgrades Added!
Vložit
- čas přidán 29. 08. 2024
- In an earlier video I assembled a DC generator to run from a Honda GX160 engine. It's been so useful since that I've rebuilt it with some upgrades.
There is a new custom carry-frame made from 1/4 inch steel plate and some BSP pipe fittings (thread-locked solid). The belt drive is now a chain drive and the dynamo (motor) has been changed for one with holes in so that it runs cooler. The fuel tank has been changed too.
This video is it's first test. I plug it into a massive 12v battery (1500AH) that's only 1/2 charged, then start it up.
As it's a DC motor, I don't need to pull-start the engine, it starts itself just by connecting the battery to the jump leads.
With the engine idling it was making about 15 amps but after progressively cranking it up, it was putting more than 90 amps into the battery.
The dynamo/generator is actually a 24v DC motor made by Bosch that I got cheap off eBay. Apparently these specific motors are becoming sought after as motors for electric bike conversions and go-karts but there are loads of other suitable motors around that would also work well.
![Lawnmower Generator [ARCHIVED]](/img/n.gif)
Watched several of these and this is the only one actually operated and tested. good job, Id like to try this to charge my off grid system in winter or when using tools that drain the power.
I just learned something today, thank you! The DC motor idea is quite a clever way to start the ICE. Good luck with the chain tightening being another idea I liked.
Thanks so much Zwarst for the nice comments, and I'm really glad the video was of use to you. I did get the chain tighter in the end!
This is both brilliant and gorgeous. I love how you built this. Those gauges are retro cool.
This is exactly the sort of video I like no flashy graphics intro or worse "music" just well presented clear diction easy to follow, my hat off to you Sir !
you just got another subscriber Cheers
Thank you so much Poroldchap, that's high praise indeed. I'm trying to improve my videos, my earlier ones were very waffley I think, so trying to be to the point and not over-do the detail. Looking at your own videos, I reckon we are of a similar mind so I've subscribed to you too!
Hi POC, great to see you popping up on Miles channel, I've no idea why Miles is not more popular on CZcams.
@@TheAmazingAdventuresOfMiles Miles, you will love POC's channel I've been a fan for years, POC is very very talented and entertaining, highly recommended.
Hey thanks for the content. I live offgrid in Alaska and keeping the battery bank full in the winter is always a challenge. Plan to build one of these 12v chargers soon.
Thanks its informative and might be be very useful to some people in certain situations/ However running some numbers it is lacking in effientcy
The engine specs are 5,5hp flat out suggests it is about 0,5 lbs fuel per HP or 2.8 lbs per hour 1.25 kg (1.8 litres ) is 15000 watts or 15 kw . Thee output is 90 amps x 12 volts or about 1000 watts or 1 kilowatt ' In put 15 output 1 makes about 7% effientcy i calculate which is to be expected from small less efficient engines compared to larger engines. I dont think a Alternator will return any better results but i could be wrong
Absolutely amazing - just what I need to power my 64amp trolling motor on my boat in case of emergency - will be building one of these one day, to replace my petter diesel - thanks for that
lol yes it would push a trolling motor very well I should think! Would run for hours on a 4 gallon can of unleaded :)
@@TheAmazingAdventuresOfMiles I had to reply because, this morning I got up and your 5month old reply came through at exactly the same time as my 80amp circuit breaker for my motor came through my letter box - the last piece of my system. I had spent the night wondering how I was going to get through the Caledonia Canal with just solar - this is obviously the answer. Can you please tell me where I can get a DC motor like yours from? Thanks, Adam (ps - you can see my setup on my channel - I would most appreciate your help)
@@saraofnorthwales Hiya Sara! Yes it took me a while to notice your message. I get notifications of replies now! I've got a small one you can have if you want, if you're in N Wales at the moment? Otherwise, eBay is generally the place to look.
@@TheAmazingAdventuresOfMiles That's a good idea. I am currently in Herefordshire and will be returning to North Wales in a few days, most probably. My trolling motor is about 800w so it's not that big, I am hoping to run via a largish 300AH battery bank which I would like to charge somehow when in a canal.
That's an awesome setup!
Hi, I've only just seen your video, for some reason CZcams has only just recommended it. I built a 24v version using a truck alternator on a 9hp honda as I live off grid and some days the sun doesn't shine nor the wind blow so a backup is essential. I like the chain idea instead of a belt but my one question is why did you adjust the idle speed screw on the carb and not move the throttle lever that works against the governor spring? That's what it looks like.
Nice and quiet
Your voice on occasions reminds me of a younger version of Tim from the channel Grand Illusions.
Nice work! Looking forward for more videos!
Thanks so much Flack3, really appreciate it :)
I really appreciate your videos! My Dad made something like this with a 3.5hp Briggs engine and a car alternator and small inverter. Anderson connector provides versatility. I think a perm magnet motor would outperform the alternator? I have a small 700ah home battery I would like to supplement charging with this type of system. I also have a 6v generator from my 70 yr old farm tractor- would this be of use to me? Your projects are inspiring to me and now I want to make something like this. I do not have your knowledge of electrical as I am more on the mechanical side. Thank you! Looking for pm motor
When you charge a lead acid battery 🔋, your generator needs to provide 2.5 Volts ⚡ above the battery 🔋 voltage.
12 volt battery needs 14 Volts from the generator.
Crackin' little gen there mate! Needs one of those for me little Trailer Camper Build I'm doin' so I can put Kettle on while I'm at it here in NZ ;)
Thanks for the comment mate I hope you get set up with something practical, as tea/coffee is essential and I don't think I could go anywhere without that.
@@TheAmazingAdventuresOfMiles Cheers Mate!
Excellent ! thanx
@TheAmazingAdventuresofMiles What a beautiful project! For people who want to do this project, what is the best way to make a platform and carrying handle for the genset?
One comment;
Why didn't you connect motor and gen directly. Shaft to shaft with rubber connection.
Great job sir.
Thank you Rehman, much appreciated :)
Love your videos. Maybe a twin belt pulley system would stop the slippage? Have you any ideas to regulate output to stop overcharge. What are the Bosch motor specs?Hope you make more videos. Cheers
Hiya John and thanks for commenting :) On this generator I actually use a chain, so there isn't any slippage, but an earlier design of mine did use a belt and sometimes that did slip a bit. The Bosch motor is rated to 800w I think, maybe 1000w, so at 90 amps that's the top end of it's rated current. It's a very tough little thing, well made and sturdy. I've not bothered with a regulator as you can see, I just turn it off when they batteries are full, but it would be very easy to do this automatically. You could use a solar charge controller, or a voltage sensing relay would work fine, these are pretty cheap on eBay. You'd wire it so that once the voltage reaches a set level, say 14.4v, it just disconnects. It would also be easy to have it fire a second relay to stop the engine, if you wanted to be super fancy :)
Cheers John! Miles
Are you using any type of charge controller? I'd hate to blow up my batteries.
Hey there Troy, No I'm not because I just watch the battery voltage rising and when it reaches about 14.4 - 14.8 I stop it charging. If I left it beyond that it would boil them into oblivion.
If a more automatic system was desired, putting in a 100a MPPT solar charge controller would do a fantastic job and manage it all itself. But that means buying a 100a MPPT solar charge controller and they are not all that cheap.
Good video
Miles, if you have five minutes (actually 3.08) have a look at Nathan Amos Engineering's video on the Lister D charging set, not as mobile but stunting.
Looking very good. I am planning to have a similar setup for my 24v system. I was thinking to use an alternator. I don't understand how that dc motor starts the engine and then it reverses back.
Will the same rule apply to the alternator?
Hello Baris and thanks for writing. The motor works normally when spinning the engine off the 12v battery bank, but the second the engine starts, the engine runs faster. Like when you start a car, the car starter motor turns the engine over more slowly that its normal running speed. In the case of my generator, current flows from the battery to the motor during starting, but when it starts and speeds up, the voltage from the motor is greater than the battery voltage (because it's turning faster now) so it just flows the other way instead.
To put it another way, both the motor and battery can send or receive current, and it will always flow from whichever is a higher voltage to the one that is a lower voltage. I've probably not explained this very clearly.
An alternator won't be able to start the engine, if you apply power to it then it won't do anything because it has a bank of diodes in it that only allow current to flow out of it, not in. Even without those diodes it wouldn't work because the alternator internally operates as three phase AC, but the current from the battery is DC, so it wouldn't turn without clever electrics to deliver AC from a DC source.
So the trick of starting and generating from the same machine does require a DC motor. Unless, like a car, you have both hooked up, a DC motor to start it but use an Alternator for the power generating.
Whether you use a DC motor or an alternator is entirely up to you. It is generally held true that an alternator will make more power, but not always. Some car alternators max out at 60 amps, whereas this DC motor can make more than 90 amps, so it just depends on the size of the machine you choose. An alternator could be said to be longer lasting due to it's lower mechanical stresses but that's not to say that a DC motor is unreliable, a well made one will last years and years.
So there are pros and cons either way. If you're not bothered about the electric start feature and simply want to charge batteries, I'd be inclined to use an alternator. In my case, when I put this together I didn't have a spare alternator lying around but I did have this very good little DC motor left over from another project, it does a perfectly good job as this video shows.
@@TheAmazingAdventuresOfMiles thanks for the detailed response.
@@TheAmazingAdventuresOfMiles Very well explained, you're engineering is also thoroughly well thought through. I can't work out if you are an educator or mechanical engineer or indeed a miner. I hope YT gives you the publicity you deserve. Liked and subed.
Would this be considered a continuous safe amperage for a battery bank drawing say 2500 to 3000 watts, for an off-grid RV?
It looked like about 15v output? was that natural output or did you regulate it at all? I want to use a treadmill motor but i think voltage would me much higher.
Hello Lyle! Well the voltage depends on the speed it's turning of course, but you can work out easily what to expect from what it says on the motor. For instance, on this one it's a 24 volt motor, and if you give it 24v then it spins at 3000 rpm. So when you turn it around and spin it at 3000prm, you get 24v coming out of it. With a little engine like this the speed can be set to anything from about 1000rpm at the low end up to about 4000rpm on full blast, it's just a little screw to adjust it. So I just put a volt meter on it and adjust the engine speed until it's around 14.5 - 15.0 volts, which is ideal for charging 12v batteries or running 12v gear. I guess the engine is running about 1600rpm or so.
If your engine/generator combination needs it you can of course alter the size of the pulleys/sprockets to give a different gear ratio. I don't know what the voltage of your treadmill motor is, lets say it's 120v DC, well you'd want to run it at 10% of it's rated speed to get 12v out of it. or 15% for 18v. Or 20% for 24v and so on.
You do tend to find that if you are spinning a high voltage DC motor very slowly, the power coming out of it will be a bit weak in terms of amps. I'd advise going for a motor that is roughly in the ball-park of the voltage you want to get out of it. If it's low voltage DC you want maybe consider like a cordless-drill motor, or an electric scooter motor. I know you saw my other DC generator video where I used a dirt-cheap motor that was a spare part for an electric lawn-mower that was long out of production. Lots of suitable stuff about on eBay and such.
A better way to control current is to mount a solar charge controller between generator and battery, then the generator output will be regulated by the controller disregarding of voltage output from the generator, plus the charge controller will charge the batteries correctly.
Great info from you guys.. i’ll try it😀
Mighty thin wires for such high current
I guess you mean on the power-meter. I agree! But, that's how it came. I don't use the generator with that power-meter in line, that was just for the video.
@@TheAmazingAdventuresOfMiles the output wires from generator to the first plug, look like 25 amp max. Just my opinion of course.
@@richardgray115 Ahhh I see what you mean now. I think they look thinner in the video that they actually are (they are the ones it came with) but yes 90 amps seems a lot for them. Mind you they don't seem to get warm, probably with all the fan-air blowing around there.
How are you limiting the voltage to stop overcharging the battery
Hello David, Great to hear from you! There is no regulation, would have to make sure its stopped when battery reaches 14.4v but you can get voltage sensing relays that would do it automatically
@@TheAmazingAdventuresOfMiles I would think that would also limit the ampage also as it would shut charge off every time it reached 14.4v I noticed at 50amp the voltage was 15 or so volt but this is power side not sure what battery side would of been I would think alot lower out of all battery set ups I looked at forklift truck ones still seem the best all round to me love the idea of the battery to start the engine then charge once rpm picks up
Please be careful and don't be running 18 volts into the batteries like that! Nice little motor. I'll see if I can find me one!
Thanks blackz06! It was just a short test of amps potential, I wouldn't really charge lead-acid to 18v but stop them around 13.8v. Actually since making this video I've used an MPPT controller between the generator and the battery which does all the work for me and just takes care of the whole process. Yes it's a good strong 24v motor I recommend it but it does look like they've become very popular as a traction-motor for home-made electric bikes and so forth, so they tend to fetch quite high prices on eBay. I got lucky with mine as I didn't pay much for it, but there are loads of actually very good 24v permanent magnet motors around for very little money which would also be fne.
@@TheAmazingAdventuresOfMiles I never seem to be able to find a deal on motors like this. :(
hi could l get it to make 48volts .cheers adrian
Do you have a part number for that motor or it’s original use? I’m building similar at the minute and used a Chinese MY motor that is pretty poor 200 W at the rpms I want to run..
Hi there. Yes I do, it's a Bosch 24v 750w motor part number 0 130 302 014. A quick look on Google found a few suppliers, none actually on eBay at the moment but they come up quite often. If you're in the UK like me then this company does them for 239 pounds inclusive, that's brand new, I think I paid around 100 pounds for mine second hand if my memory serves www.autodoc.co.uk/bosch/664210
I think they are worth the money. A lot of cheap Chinese ones about at a very good price at the moment but they are built like rubbish, I wouldn't run an electric toothbrush with one.
i doubt 15+ volts is good for your battery.
Probably not unless you are doing an equalize on the batteries. Also you never want to charge your batteries more than 20% of their capacity. To put 90 amperes into a battery it’s AH rating needs to be at least 450 for wet cell or AGM batteries.Personally I would never charge a battery bank more than 15% of its AH capacity. I have a battery bank over 20 years old and the batteries still past a load test with over 90% of their capacity. I use a Honda 2000 generator to charge my battery bank when I don’t have enough sun. I can control the charge rate to my batteries to a safe level and run the generator on eco-throttle so as the charge tappers off the generator slows down and uses less fuel. Honda generator cost when I bought 2 of them was $1,000 each 20 years ago. I worked in telecommunications and use the same practices that were industry standards for battery banks.
@@Chris_at_HomeYes, for people not that much into ah amps and so on, rule is it has to take 5 hours or more to charge up your battery from 100% dod, 2,5 hours or more to charge it from 50% dod, else you're cooking it with too many amps. And if one wants their battery bank to last 20 years like yours, do as few discharges over 50% dod as posible.
What are the specs horsepower of the engine and the specs amps horsepower volts of the Electric motor
Hiya Lionel, it's a 6.5hp Honda I think, and the Bosch electric motor is rated at 24v and, I think, 800 watts. Which would put it around the 35 amps mark, if was actually being used as a motor.