DIY DC Generator: charge batteries off grid

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This broken treadmill has a good DC motor inside. In this video I pair it with a gasoline engine to build a generator that can charge batteries. It was a fun process. I can now charge 12V 24V 36V and 48V batteries. This is useful when off grid and no solar production.
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Products in video may have been provided to David Poz, LLC at no cost for the purpose of the review. All views and opinions expressed are that of David Poz, LLC.
My videos are in no way intended to be instructional "how-to" lessons. I am simply documenting my project for informational purposes. Property damage, personal injury, or death may result, even when following manufacturer's instructions. I cannot be held liable for such damage or injury. It is YOUR OBLIGATION to ensure that you are complying with any local and federal laws as well as code and permit requirements.
David Poz, LLC

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24 сен 2024

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Комментарии : 948

@ScottPlude Год назад

I did a project similar to this several years ago. A harbor freight 5hp engine connected to a 60 amp auto alternator and a standard car battery (optima yellow top) to keep things simple. It was intended to allow ham radio operation in a grid down scenario. I welded a small frame with casters and it worked very well. I still have it in my garage. Works well when I see a dead car battery as well. Roll it over to the vehicle, fire it up and in just a few minute I have a healthy battery again. I used large anderson connectors with battery clamps to make it modular and useful for many scenarios. Your scenario is a bit beefier for powering an entire home but the concepts are similar. Great minds think alike!

@alasdair4161 Год назад

Interesting, I also built something very similar back in the 80's using a tiny 1.5hp side valve Qualcast Suffolk motor and the smallest alternator I could find, I made my own multi chamber muffler and built a minimal sized lightweight moly frame then added sound absorbing panels to deaden noise. Originally intended as a camping generator (also the reason for quietening it as much as possible) I still use it as an emergency power source to this day. The alternator self excites so I also squeezed in a small inverter which can run lights and small appliances and it runs all night on a couple of litres of fuel.. It's small, lightweight and very easy to start and is also very quiet, the antique motor has long stroke for it's size and just chugs away quietly as dependable as can be. Variants of this can make great project builds for anyone. About fifteen years back I stripped it down, sand blasted and powder coated the whole thing and now it looks better than ever, and it should last almost forever. Cheers.

@Banzai1338 Год назад

If you put a stage 2 or 3 kit on the predator you would be able to get about 15 to 17 horsepower no problem

@BLAZE13011 Год назад

Ive thought of doing the exact same thing still haven't gotten around to it yet but at some point I will

@hodwooker5584 Год назад

I built a 13.5 vid version of this with a Chevy one wire alternator. I direct coupled the alternator and engine(4.5 hp) with a love joy type coupler. The coupler I used came from epicenter’s website the alternator half of the coupler needs to have left hand threads. You could at that time also get parts for belt driven alternators from them. I hope they are still around. I can get 25 amps out and it takes about a half hour to recharge my trolling motor battery’s. So fish all morning, eat lunch and charge battery’s.

@hodwooker5584 Год назад

(4.5 hp)

@LitheInLitotes Год назад

This is really valuable and I hope you follow up with a bigger engine. As you know, the idiots out there selling 48v DC generators want to rob people for 3K. One guy tried with alternators but failed. A treadmill motor is plentiful and it was genius to use the charge controller.

@DavidPozEnergy Год назад

Thanks for your comment. I'd like to try again too with the bigger motor.

@Trialnerror Год назад

Hey, I got it figured out....eventually :)

@johgude5045 Год назад

@@DavidPozEnergy I can recommend the QSMOTOR 120 . Should fit your project well

@stevennope8864 Год назад

Might want to re-size your pulleys for increased torque output. Obviously you'll lose top end speed, but you might be able to get a nicer middle ground, where the engine will work for the application. The engine should be able to run without stalling with some minor adjustment of the ratios. Also, might be able to sacrifice a lawn mower deck for the spring tensioner pulley. Or buy one at a hardware store. That might help reduce some of the vibrations, particularly when loading and unloading the motor. Excellent work as always. The only problem with adjusting the pulleys is that it won't be as efficient for operating at the lower level voltage loads.

@stevennope8864 Год назад

The pulley on the motor would be easier to adjust, lol. Maybe just a 75% reduction in outside diameter? You might need to play with it a little bit. It will be easier to go bigger than smaller, because you will start causing belt slipping if you go to small, but that would require redoing your welds. If you go that route, might want to weld a quick change setup to the motor, so you can easily adjust depending on circumstances. Could also do dual pulleys on each shaft, with different sized pulleys for each load. Then you can switch the belt to the corresponding pulley set.

@carrollmcpherson4530 Год назад

This right here is where I would start unless you wanted to buy a larger engine all along! 3 HP aught to get you a lot closer to 1800 Watts than bogging down at 900w.I am guessing that gas engine was meant to make its power at around 3600 rpm and the dc electric motor was meant to be run at around 1700-1800rpm. So your gas engine pulley may need to be half the size of the elec. motor (generator) pulley. This would at least be a good starting point. An even lower ratio (say somewhere around 2.3 to 1 instead of 2 to 1) might be better to ensure you don't bog down the little one lung china bomb creating high head temps and hot valves.

@bretk7916 Год назад

Steven Nope, larger pulley on the engine will increase your torque and increase RPMs on the motor/generator

@troy3456789 Год назад

@@bretk7916 He needs *just* needs to increase the pulley size on the now DC generator, at least 1.5 times bigger. It will slow as a result, and the engine will be able to turn it easier because it will have more leverage on it to do so. I think a chain and sprockets would be better, last longer. His engine flywheel is desperately calling for a clutch to be able to engage or disengage

@Steve25g 4 месяца назад

@@bretk7916 bigger pulley size on motor reduces torque. You need a smaller pulley on engine, or a bigger on the dc motor

@magic.marmot Год назад

25 minutes in, as you're tightening the belt, watching the standing waves in the belt sort of "tune in" as you tighten it is lovely.

@apollo280zx Год назад

Quick tip- treadmill motor shafts are typically LH threads to prevent the flywheel from coming off during operation. Yours is no exception as you can see the LH threads at 2:18. So to remove it you'd need to turn it clockwise if looking at the flywheel head on.

@schoen88ss Год назад

Hope he reads his comments. He put the whole thing together spinning the flywheel the wrong direction. Bad things will definitely happen if the treadmill windings fail or are overloaded.

@LITTLEEXPERIMENTCHANNEL1 Год назад

Thought this, you got there before me right at the top of the comments. Bravo!

@Capoe3 Год назад

Commenting for David to see.

@leopoldpoppenberger8692 Год назад

@@Capoe3 also mount your electronics separately =no vibration

@horacepinker6578 Год назад

I remove the plastic fan at back of motor put the exposed shaft in the vice so cant spin and unscrew them . Like you mentioned its a reverse thread. Can use oil strap wrench or plumbers wrench to get good grip. Worst case scenario grind two flats onto opposite sides of the small pulley and put a shifter on it and smack it with a hammer to loosen it. ( some have locktite)

@boblatkey7160 Год назад

I've lived off grid for 24 years and I did this with an engine and a vehicle alternator that I bought from a rebuild shop and charged batteries for my household. It worked great for about three years!

@chrisellingson123 Год назад

Very interesting project. I have a few suggestions. A centrifugal clutch would make starting easier. This will also allow you to warm up the engine at idle before loading the engine at running RPM. Unfortunately a typical MPPT type charger designed for Solar will 'hunt' for the max power levels this means the load on your motor (generator) and engine will vary/cycle. I think a work around for this is to limit the battery charging current setting to the below the max continuous power values of both the generator and engine for longevity and running effeciency. I would be temped to do an LPG conversion and implement a dual LPG/Biogas fuel system.

@davidschwartz5127 Год назад

Running on LPG mean less output in power from the engine.

@truck655am Год назад

The Victron MPPT isn't cheap and you can set the Max charge current to that of the engine so it won't go over of the max capacity of the engine. Removing the charging cable ensamble enable it to restart the engine with a drill every time with no problems.

@randacnam7321 Год назад

There are MPPT charge controllers that have wind and hydro modes and/or the ability to set a fixed input potential. Those would play better with a DC generator input.

@stevec5000 Год назад

He already has a motor to use for starting. Just apply the battery voltage to the DC motor to start the engine.

@jdcairncross3631 Год назад

@@stevec5000 exactly !

@TabooRevolution13 Год назад

I use a 4HP tredmill motor on my bicycle generator. It's changed my life. Sometimes I'd now prefer to charge it than to use it. Great way to get fit off your internet addiction!

@bencapobianco2045 Год назад

Love the project I’ve been collecting parts to build one for a while now. My suggestion is the treadmill motor is a permanent magnet motor so with the 48 volt batteries you could wire in a solenoid, some diodes and a switch to use the treadmill motor as a starter motor for the gas engine. I’ve had old tractors that use a DC motor as a starter then when the engine starts it works as a charging system. Old tech you should be able to adapt that concept pretty simply. Great job can’t wait to see version 2.0!!

@foodstampz 11 месяцев назад

Interesting

@alainmcin 9 месяцев назад

Hi David, I enjoyed watching your project.... I did something different, I took 120 volts output from my house generator, connected to a full wave bridge rectifier (1000V, 100A)...connected a capacitor(1000 microF, 450 volts to the output of the bridge, and fed that to the solar controller....because my controller is limited to 150V max. input, I adjusted the generator regulator to give 100 volts on the mains...since 100x 1.414= 141V.olt ( minus 2x diode voltage drop)...so I get around 140 volt max....this works quite well....I pushed 2.5 kw into the batteries....cheers

@noanyobiseniss7462 Год назад

Just change the circumference of the pully on the motor.

@Chris...S Год назад

Agreed, changing the gearing will allow for more torque

@wg6215 Год назад

He needs to match the peak rpm for max hp plus he needs to know what rpm the electric motor runs at also then gear them accordingly

@Sturgiselectric Год назад

With the charge controller and the knowledge that the dc motor is 130volt. You can use the phone app and adjust the motor rpms until you show 130 volts in the app. A slightly larger pully on the motor may overcome the bog down when under load. Hope this helps.

@paulpierce2051 Год назад

@@Sturgiselectric i think you want smaller on the engine and larger on the d/c motor? It seems to me the gas engine isn’t running at high enough RPM due to the load.

@michaelmain1990 Год назад

Agreed pulley ratio would help alot

@P_RO_ Год назад

Shades of the old Jeremy Fielding 😎 A few thing here. This type of engine is designed to run against it's governor at full RPM's or just slightly less under a full load. "Bogging" slower loses HP and tells you the engine is producing all that it can and this is your load limit. Changing pulley sizes will not get you any more power, use that to achieve the load RPM you want. Have the belt loose for starting, and use a smooth-faced idler pulley from a junk car to tighten. The spring tension on those is too high for a single belt, but a hand-adjusted threaded adjuster of some sort should be easy. The engine and 'generator' need to be mounted as solidly as possible; anything that bends or flexes will amplify vibrations. Use rubber mounts or feet under the whole assembly if vibrations are a problem, remembering that vibrating wires break quickly so secure those well. The electronics are on you as you know that better than I ever will. I ❤ DIY and repurposing, especially when the parts can be had for free. I only subb 2 YT channels on this topic and yours is one: Straight shooting, no BS, intelligent, and everything covered in depth but using language anyone with an interest can easily understand.

@opennrgdotcom Год назад

The Flywheels are left threaded. Fan pulls straight off with some effort. Pull the brushes out and the brush end off. Vise grips on the rotor shaft where the fan was. Turn the flywheel clockwise to loosen. Opposite of the Righty Tighty rule.

@Teknopottu Год назад

Great explanation.

@flojotube Год назад

DUDE .... where have you been all my life???? I have a dozen of these motors and GAVE UP trying to figure this crap out.... UNTIL NOW!!!! 🙏

@d_ward4871 Год назад

The amount of great input you can get from a productive comment section is amazing

@benssolarandbattery Год назад

What an awesome project! I love how you reused all of the little parts and pieces from the treadmill. Thanks for sharing!

@DavidPozEnergy Год назад

Thanks Ben.

@chrisdekock8864 Год назад

Yes, i love reusing old machines for projects! In 2017 i build a mini hay baler (4lb bricks) from an old washing machine!

@mattsadventureswithart5764 Год назад

Very interesting project, thank you. I'd like to give a little advice based on painful experience ref those little cutoff disks in your dremel. They do not take more than the tiniest lateral force before shattering into multiple sharp very high speed pieces. They really hurt and I'm very glad I was wearing proper safety goggles. Please, anyone who might read this, don't let them get the chance to explode like I did - only use them to cut, never to grind. AND as Norm always told viewers: wear safety glasses.

@stephensmith6055 Год назад

Ive had some troubles with off brand and cheap disks also. my advice, the cheap tools are great, the cheap consumables, will cost you.

@magic.marmot Год назад

I love that you did this. I have a collection of treadmill motors that I've wanted to try something with, though my idea was more centered around a vertical axis wind turbine. I also wanted to try using them to propel a small electric vehicle (like a garden tractor), but the threaded-on flywheel doesn't work very well with reverse polarity. Under a heavy load, I suspect that the brushes will wear out sooner than expected. I haven't looked to see if the brushes are replaceable. For a low-cost backup unit, this is pretty stellar. Always amazed, good sir.

@DavidPozEnergy Год назад

A vertical wind turbine would be great.

@richardbilous5338 Год назад

I miss hanging with ya David! My smart buddy! Thanks for watching me all those years! I cherish all the days you tought me things! I still think you should be a teacher! You tought me things faster then anyone in this world could!

@NoelBarlau Год назад

Really interesting to see the MPPT controller bogging down the tiny gas engine trying to maximize output wattage. I've had this same thought pattern regarding direct DC charging for my 48v Lifepo4 battery bank using a Lister CS 6hp single cylinder diesel, and this setup would come pretty close to ideal. The general rule is 2hp per 1000w output, so a 6hp diesel at maximum rated constant power should be able to output 3kW DC on a continuous basis. Still looking for the "perfect" solution for that equation. Great video, thanks very much for sharing, it was right up my mental alley.

@DavidPozEnergy Год назад

Lister engines are pretty darn cool. Thanks for sharing your thoughts.

@carljacobs1287 Год назад

Actually the "MPPT" part of the MPPT seemed pretty poor. Surely it should've backed off the power drawn once it started going down, since isn't that the point of the fancy algorithm. You should alert the charge controller of this video, as I'm sure it should've been able to target around 1000W continuous.

@petersack5074 10 месяцев назад

Wisconsin, air-cooled engines, are also ?....' cool ' too !

@michaellane4762 Год назад

I like that you are trying to design charging systems for people who want battery back-up but can't use solar. Carry on you will get it right. Mike

@keithcress1335 Год назад

Hi David. Fun project! Normally you get about 500W per horsepower of the IC engine. With smaller setups you should probably consider more like 400W/ per horsepower. 1,800W/400 = 4.5HP. So you're in the ball park. The ultimate limit is the engine speed. For you to get the engine's rated horsepower you must run it at the speed the rated hp is specified as. You need to change pulley size to a smaller one on the engine or a larger one on the generator. Also, the generator will only supply the watts it can at a particular speed. If you turn the generator slower it will automatically limit it's power output. By messing with the pulley diameters you can set the gear ratio to whatever generator power the engine can support at the engine's speed sweet spot. Ditch that generator pulley. Cut it off with a grinder. Grind a slot parallel to the gen shaft into the pulley. When you get down almost to the gen shaft it will likely slide right off. Doing this would let you keep the engine pulley as-is. As a guess I'd make the generator pulley the size required to have the generator turn 80% of the engine speed. These wing-it jobs with engines and loads (like a generator) often take iterations of drive ratios. With a little trial and error you should find a place where the engine can run without straining ~80% of it's rating all day.

@rearspeaker6364 Год назад

1hp is equal to 746 watts.

@LibertyDIY 6 месяцев назад

@@rearspeaker6364Is that affected by the efficiency though so you only get 400-500 watts out of it?

@rbartsch Год назад

A direct drive is more efficient than a belt. Because of the low torque of the gasoline engine I suggest a gear/transmission ratio. You can also try to disable MPPT in the Victron charger or limit the charging current. If you connect the gasoline engine with a clutch on one end of the generator-shaft and a Diesel-engine with a clutch on the other end of the shaft you get a multi-fuel generator. 😉

@ozimandia Год назад

Is there a way to use a gear or another pulley to proper balance the system? I think that it will not only fix starter issue but as well get the maximum torque for the motor, there are calculators to help find the diamiter, but the real work will be in retrofit an reduction / balancing system in the setup.

@reyes2009 Год назад

David, yoy should try a lawn mower motor with an alternator. That would be a much more potent mix. Btw, the rubber between the motor and the frame is contributing to the e vibration.

@dominiclavu193 Год назад

Love your ingenuity and effort! Ways to recycle "old, useless" equipment...that's a way to save money. Kudos!

@galen__ Год назад

I recommend watching Robot Cantina from Episode 1 in 2020 for some videos on maximizing your Predator engine. I’m sure that you’ll max out the treadmill motor soon enough. Can’t wait to see this 👍 edit: They used the 212cc engine whereas yours is 79cc oops. I still think the 79cc can do at least 2x the 900W with a few additions like a torque converter, as others have said. These seem popular in gocart and minicycle circles for lighter weight options, but maybe hasn’t got the same attention the 212cc has or the bigger heavier others. Would be great to see an affordable 48V DIY generator using the 78cc or 212cc engines 👍

@drevil4454 Год назад

Most eco friendly off drid projects. An engine for everything. Love it!!

@donscottvansandt4139 Год назад

Awesome build! I think one problem with the hard start is the big harmonic balencer also could go with a smaller drive pully and a larger charge pully .I think that would work.

@bretk7916 Год назад

Larger charge pulley would slow down RPMs and smaller motor pulley would sacrifice torque I think smaller charge pulley and larger motor pulley is what is needed

@troynyholm232 Год назад

@@bretk7916 I believe you are incorrect...lower the RPMs will result in higher torque. Decrease the diameter of the drive pulley and increase the driven pulley will lower RPMs and increase torque.

@chuckrussell6740 Год назад

Great job demonstrating eyeball engineering. Know that the Light of your being is a blessing to everyone on your journey. Shine on

@RevM Год назад

Awesome idea David! I've got an old treadmill in my scrap pile that I had intended to haul off to the metal recycler ... I think I have a new purpose for it now!

@DavidPozEnergy Год назад

Cool. The motors are worth saving.

@Teknopottu Год назад

Metal recycler? I had to hunt down for months to buy a used treadmill motor to test with generators. Here in Finland there are fewer treadmills.

@landonferguson7282 Год назад

Maybe try setting a maximum charge current for the charge controller, to act as a governor for the engine, so the engine speed can stay within its correct range.

@nunolourenco1532 Год назад

^THIS! I mean you need a governor, one way or another.

@LibertyDIY 6 месяцев назад

Yeap that would have been an easy fix and stabilized the output

@dadbain Год назад

Good effort David, now I'm looking forward to version two.

@bruceeverett5372 Год назад

A 79cc motor is common in small inverter generators but it turns at 5000rpm to get the hp required, but these little thumpers are only for around 3600rpm so they can't get to that power curve. Get a Predator 212cc and it will make all you need!

@keithwithnobs Год назад

1 hp is or equals to 746 watts. Looks like you need a 6hp gas motor. As you are overdriving your generator with a bigger drive pulley than the driven pulley. So you need to do some math. What is the rated rpm of treadmill motor. All small gasoline engined are rated hp at 3650 rpm. Need to get pulleys to match reccomended rpms of each unit. Also consider mechanical loses by the belts and bearings. It will work. When you do get. Build a small hydrogen generator and you can run your unit of just water n baking soda. I run a 12 500 watt generator on hydrogen. I. Use a 10 amp battery charger off my generator output to power the electrolosis. I start the gas engine on gasoline. Once is running and producing electrical power i switch off gasoline and over to hydrogen. I enjoy your videos. Very well done. Hope you have success with DC generator.

@DavidPozEnergy Год назад

That's awesome you run yours on hydrogen.

@keithwithnobs Год назад

@@DavidPozEnergy Easily. The engine on my 12 500 is 13hp. It takes about 8.7 amps to make enough hydrogen to run it. So for you. You could make a generator that only uses 5 amps 12 volts to make enough fuel to run a 6 hp engine. My water mixture to make hydrogen is 4 tbsp of baking soda to 2 litres water. It converts fast and resists cold weather eg. Freezing in low temps. A tip. Use a daul fue carb conversion and feed the low psi hydrogen into lpg regulator. You will need to adjust for hydrogen. But it sure makes it easy to run hydrogen on gasoline generator with varying loads.

@onlyscience7120 Год назад

Energy can neither be created nor destroyed - only converted from one form of energy to another.

@bobbinatorrah67 Год назад

Great video. It really shows how much power several hundred horsepower is, and even gives me more respect for 400W solar panels.

@dankelley9361 Год назад

Great idea, love your ingenuity! Would’ve like to see better where & why all the wires went, and exactly what functionality each device provided, like the charge controller & the choke.

@jacksin3323 Год назад

Key tip... those motors can make for great grinder motors. Ive saved 3 from the scrapyard, and made a beltgrinder, powerhammer, and wheel grinder.

@Ash1965.. Год назад

Hi I use a car alternator 120 amps I tried a 2.5 hp and had your problem so went to 6.5hp. You could also try changing pulleys like a small one on your motor

@DavidPozEnergy Год назад

Nice. Do you have any posts about your alternator project?

@Ash1965.. Год назад

@@DavidPozEnergy no just look and learn yours covers a lot I didn’t know cheers

@IAMElectric369 Год назад

I love treadmill motors!! I have about 12 currently. I’ve got one that you have there too. That motor is a hoss! I built a generator using two of them, a single phase motor winding and some very strong magnets. Machine produces usable a/c and d/c at the same time. Would love to tell ya about it. Tip for you in your generator, Convert to a/c, clean it up then back to d/c. Microwave transformer. Step Up. Capacitor.

@DavidPozEnergy Год назад

Sounds good.

@michaelorr430 Год назад

Fun project! You can set that up with a "loose/slipping" belt then add a lever with a tensioner pulley so that you can easily start it , then pull the lever to bring the tensioner pulley up against the belt to engage the generator. You may be able to change settings on the charge controller to set the max charge amps considerably lower so that the generator doesn't bog down to an under voltage and low rpm condition, Tinkering is fun and I enjoy your videos, keep it up!

@offgridwanabe Год назад

I like the idea of using a DC motor for charging the battery bank seems you need to know the rpm required to reach the watts you want then size the pulleys to make that rpm you may not need another gas motor but even before you started I figured 5 hp needed (just guessing) so much power lost in the belt, an old snowmobile engine with the clutch pulley may be interesting. Thanks for sharing and letting us see your process.

@Ghergyjubles Год назад

Great video and idea.The amount of reuse from that treadmill is amazing. Could play around with pulley sizes, but you probably are limited by the motor itself. And maybe weld some cross bars on the bottom of the motor supports to try and keep vibration down.

@jayw900 Год назад

The motor was fine, it's the engine that was a bit undersized. Could also be a pulley ratio as well.

@backyardmachinist Год назад

This is great! You said that the engine is 3 HP. Combustion engines are at best around 36% efficient, so it makes sense that it was only pumping out 800 of those twenty-two hundred theoretical watts. Great to have the ability to generate power with another source tho and keep your off-grid operation going! Thanks for sharing

@DavidPozEnergy Год назад

Your welcome, thanks for watching.

@volodumurkalunyak4651 Год назад

@@DavidPozEnergy wrong. 3hp combustion engine is supposed to have max OUTPUT power at 3hp - at the shaft. Output power is 3HP instead of 3hp*engine efficiency.

@Vigo327 Год назад

Loved this. I have been curious about doing the exact same thing ever since i noticed a listing for a treadmill motor from Surplus Center. I can’t fault your design assumptions since an engine rated at 3hp should be able to max out an 1800w generator head, keyword “should”. But now that you have come this far, i REALLY hope you simply upsize to the Predator 212cc and try again. The engine bolt pattern to your frame may be the same, so i believe you would simply need a different drive pulley for a 3/4” engine shaft and you will be able to start it right back up and resume testing. I think the idea of putting a 6-8hp engine in front of a

@DavidPozEnergy Год назад

Thanks for such a great comment and information. Yes, multiple MPPT charge controllers can feed the same battery, at the same time, with different sources on each charge controller. This was one of my driving forces for this design. The MPPT charge controller can be set up to the same charging profile as my other solar MPPT charge controllers, which will prevent over-charging. Anyways, I hope to pick up another engine larger engine when I can, but it all takes time and money.

@maxring837 Год назад

We made these things in the 90s to charge off grid systems and quickly realised that an engine power curve is not linear. If you consult the engines specs they often give a power curve relative to rpm then adjust your Pulley ratio to suit. You will also find you will need a much larger fuel tank and frequent oil changes and in about two weeks of running a new engine.

@johnathanstheater Год назад

Very ingenious ! Always amazed at your engineering skills. Along with your fabrication .

@DavidPozEnergy Год назад

Thank you very much!

@raymondsmith1213 Год назад

Awesome build I'm gonna do it. Ive been making windmills with these, take the cooling fan off the back and vice grip the shaft to get pulley off, left hand thread ifI'm remembering right. You can also just turn the motor on then grind the flywheel down to size like that.

@tincankiller6454 Год назад

Great video David I made a similar system except it is driven by a bicycle with one of those stationary bike stands. With more time, more modifications it can be set up for multi-volt, but for now its 12 volts, works pretty well. It's also a good work out. Stay Safe & Good Luck

@oscarvogel2140 Год назад

I made a peddle powered generator out of one of these too. They are wild DC, the faster I peddle the higher the voltage. It runs an osterizer blender with no added circuit. I used a J6 belt like the stock pully for the motor usually has and it went around the outside of a 26" bike rim. to get it going fast enough.

@djstraylight Год назад

I always thought that a small diesel engine would be great for a DIY generator. I make my own biodiesel so this has inspired me to get all the parts I will need DIY diesel generator. Probably find a DC motor in the 2kw range.

@stormer6364 Год назад

Great little project, nice idea.. I'd probably add an Ac spike suppression cap as well as the choke to prevent Ac spikes from the motor from damaging that controller, it might be a little sensitive..

@kevkev5935 Год назад

This was such an awesome video. Not sure what I'm impressed more by. The ingenuity of the build, or how tight and clean your wiring was to the charge control and breakers.

@DavidPozEnergy Год назад

Thank you. Unfortunately, there was too much vibration. So, I'll be moving the charge controller off of this setup. It won't be as neat and tidy.

@craighansen7594 Год назад

Changing the drive ratio will increase torque to the generator, how low of rpm will still produce good output? 3hp is a little small. Plus that engine does not start easily, you had to keep turning it over with the drill. Carb choke not working? It seemed hard to start even with no load.

@johnanderson2591 Год назад

I built same set up for 48 volt bank. Added large shotkey diode and intermittent toggle switch to apply power to motor from battery bank. Electric start.

@FRANK101101101 Год назад

800watts is about 1HP, the engine is clearly not producing its 3HP rated power. As someone else commented, smaller pulley on your engine for less RPM at treadmill motor but more torque.

@energetictv9340 Год назад

He would have to run it at peak torque to make it work. Many engines are over rated in small engine world. Almost need to get double the rating to get a good result

@davescorneroftheworld1147 Год назад

I did the same thing 35 years ago with a 10HP gas engine and a TRUCK alternator. I used mine to charge bulldozer batteries and other heavy equipment batteries. The DC was not as clean but all I was doing was charging engine batteries.

@ai4px Год назад

Hi David.... you should try a love joy rubber coupling. A lot less friction. Also that new EG4 100amp 48v charger from SS looks perfect for dirty power contractor grade genesis and your MEP 802.

@calcoindustries Год назад

I like running rough number math to figure out why something does or doesn’t work. You can find a video of this exact engine brand new being dyno tested and it produced approx 2.85ft-lbs peak torque. That motor is 2.5HP @ ~7000rpm with no load which equates to about 1.9ft-lbs of torque. Have to really guess on the ratio of the pulleys you attached but by a quick glance it looks like it could potentially be 1:2 which means double the rpm, halve the torque. So now your motor is outputting 1.4ft-lbs, minus any losses of belt slippage and pulley friction. Based on that, it makes sense why it bogs down when approaching full load. Diesel engines of the same HP will have a higher torque rating and the fuel consumption isn’t affected by torque load nearly as much as a gasoline engine. Love the concept, I’ll eventually build one myself in the future. Correct me if I made any mistakes.

@SoutheastOhioSolarHaven Год назад

I think the Issue maybe that the Victron Charge controller is searching Maximum Power Point right off the bat. I notice my Victron controller doing that sometimes after I reset and or turn it off. So that might be the Issue. 2.5 Hp motor with Fly wheels on it. Shouldnt be a overburden for 3 Hp engine. Try again but limit output max amps in charge controller and then adjust amps upwards . Or maybe let it run full out and see what happens.

@DavidPozEnergy Год назад

Thanks. I have been messing around with the Victron settings off camera. So far, I haven't found a way to get more Watts. I was figuring the same thing about the 2.5hp to 3hp.

@ShaneS071 Год назад

I started making a unit similar with a 24V alternator , stripped all the guts out and connected the 3 phases to a bridge rectifier that they use on wind turbines, still working on it when I get time, planing to connect it to a midnite solar charge controller, I started off with the Predator 6.5hp(212cc) engine

@maximemineault8117 Год назад

It is amazing to see the charge controller trying to maximize the output of the motor. One thing I think would help is if it is possible to set the charge controller to hydro. Solar mppt are super agressive in their quest to find the peak efficiency. If it was on a hydro or wind mode sort of mode it could be gentler and adjusting slower the maximum power point. In the video, the mppt is not dropping the amps fast enough to let the engine ramp up to try a gentler load. That said, I think it would be safe to limit the charge controller, as if you put a big engine, I think it will burn the treadmill motor.

@regularpit1508 Год назад

I have that exact treadmill sitting in a corner watching as everyone walks past that room like it doesn't exist.

@okielicious Год назад

You could hook 2 12v batt to get 24v and power the treadmill motor to start the gas engine. Like the old cub cadet riding mowers. Then reverse it back to charge mode with a switch.. just an idea! Good build !!!

@thehumbledabbler Год назад

A treadmill flywheel is always reverse threaded. Hold the shaft at the rear with a pipe wrench and turn the flywheel by hand. Works everytime.

@georgedoherty962 Год назад

The more of these that you build, the better you get. A 4 rib gates belt developed less friction.. and as someone else has already mentioned, the pulley ratios need to be investigated to find the sweetest spot. I found that using a variable speed drill or angle grinder gave me the correct pulley ratio.. My biggest success was a 2kw x 120vdc permanent magnet generator from a Chinese wind turbine. I had to have 5 different pulleys to find the sweet spot. I use a 10 horse yanmar clone. It cost me €2 000 before I got it all finished to my satisfaction. It is our standby generator that charges our 60 forklift cells. It is set to charge at a max of 12 amps x 146vdc. By tbe time it reaches 146vdc, tbe engine is pulling steady and tbe cooling fans on tbe PMG and engine are blowing nice warm air. It never runs more than 90 minutes. Mostly 60 minutes. It is the most efficient way possible for generating ones own electricity when wind and solar are not active. I built many Btiggs and Stratton x 180amp ValeoN47s. These are a fantastic success.

@DavidPozEnergy Год назад

Sounds fantastic. Do you happen to have a website, or someplace I can learn more about your system?

@georgedoherty962 Год назад

@@DavidPozEnergy I never had my own site in all the years that I was a moderator on the "Navitron Renewable Enetgy Forum" most of my projects were posted there but when the forum was shut down in May 21, all the data and posts disappeared with it. I know that it can be retrieved from "The way back Machine" with a lot of work and patience. The "Wayback Machine" Carry,s the files and archives right back to 2012.. I have not used it myself.. I don't know if you can post pics on here.

@freeinwy1 Год назад

Hey good job. By the way I’ve done a lot of fabrication and inventing for my own off grid situation. I’m a master diesel mechanic and have been off grid for about 2 years. I put an add on Craig’s list asking for old car batteries that I refurbish with my dc welder. I’ve used old treadmills for various projects. I just wanted to tell you the belt that you would’ve walked on makes a good all terrain creeper to slide under a vehicle. 😊

@kevincrawford2027 Год назад

I am using a permanent magnet motor as a generator to charge a 24 volt LiFePo4 system. Mine is driven by a water wheel instead of an engine. I had it hooked to a Epever mppt controller. When the batteries got charged and the controller cut off the voltage would exceed the controllers max input voltage. To remedy this I put a voltage controlled switch on the input side of the controller to switch the input to a load resistor when the batteries were full. I think you could use the same idea to shut off the engine ignition when the batteries are full or what ever voltage you select. Otherwise you may need to find a controller with a much wider voltage range. Been enjoying your videos.

@DavidPozEnergy Год назад

Sounds cool. Thanks for sharing.

@mudkingz6432 Год назад

A small gasifier hooked up to that setup would be a true off grid solution plenty of sticks to use.

@justincase5272 Год назад

Great approach, David! "I had fun. I learned a lot." Nothing finer!

@practicalman45 Год назад

We made a backup charger for a hefty 12v lead acid bank (normally charged from a micro-hydro system). In summer, they had low water, not enough flow in the stream for charging the bank from the hydro. The seasonal charger was powered by a 5hp Honda gas engine spinning a Ford Pickup 100 amp alternator (w/built in diodes) using the stock pulley that comes on the alternator, and a 5 inch pulley on the Honda engine (experiments showed that size optimal). The system didn't use a voltage regulator, a rheostat (variable resister coil) was wired into the alternator field winding wire. It was just set once to make the load on the gas engine at a comfortable place that wouldn't overheat the Honda but it was still working strong (too much current to the alternator field would overload the gas engine, overheating it). The voltage at the battery bank was monitored and the engine was shut off when the bank was up where they wanted it. They ran it about 3-5 hours once a day to bring their bank up full. Their gas engine worked hard the whole time it was running and it needed regular maintenance. It was more fuel efficient for them than using a portable generator powering a battery charger. They found the Honda engines were the most durable (small gas engines) for this. When they got older and tired they could lighten their load by adjusting the field rheostat down, lowering the output amps. The worn engines burned oil and used more fuel, though.

@DavidPozEnergy Год назад

Sounds like an excellent setup. Thanks for sharing.

@mitsos306ify Год назад

One of the most decent projects I've seen!

@McCuneWindandSolar Год назад

Now thanks to you I have a project I want to try and build LOL. Using an old wind turbine I have.

@andrewfong4216 Год назад

possibly the 3HP engine is able to deliver 760w x 3 = 2280 watts of mechanical power. However, that treadmill motor is probably around 30% efficient in converting mechanical power into electrical power. Therefore it is not surprising that this setup is limited to delivering ~ 800 watts.

@mark_osborne Год назад

I think you are correct

@TheWickerShireProject Год назад

Love the Idea of a choke to clean up the DC power. Sad the pull start wasn't working. Choked that should of started. New engine maybe needs to be broken in? Crazy how bad it bogs down at a higher Voltage draw. Pulley sizes will play into the build for torque. Love that engineers brain and the reuse of so many original parts to create a mount ect... We miss and love you Dave! Good video!

@TheWickerShireProject Год назад

Look into Moped Torque converters. They change in size and have different weights in them for adjustment. See and old bike somewhere GRAB IT!

@DavidPozEnergy Год назад

I miss you too buddy. Looks like you are having a blast out on the farm.

@TheWickerShireProject Год назад

@@DavidPozEnergy Rainwater system going in soon. I'm doing water filtration video's as we near construction. Felt the need to break down whatever components one might think they need and how they work or do not work as intended ( via company info or science?)

@DavidPozEnergy Год назад

That's great. I'll guess, a Jakery?

@mikeb.2166 Год назад

When the video started I was thinking you were going to be running on the treadmill to charge your batteries - LOL - like making good on a new years resolution! The video was very entertaining, educational, and great job overall. Looking forward to the next one where you modify this with some of the viewers suggestions.

@DavidPozEnergy Год назад

Thanks for watching. Yes, I'll do some more testing with viewer suggestions.

@experimentmagnet Год назад

Yup... just change the pulley ratio. The engine is only 3hp at peak RPM. I could tell by the audio in the program... it needs more HP at LOW RPM to get to its full potential. Smaller pulley on the engine. Also... that is a treadmill MOTOR... Double Pole Double Throw switch (DPDT momentary).... hook it to a battery directly for a starter.😃 All in all... good video idea! And i am very picky on these .👍🏻👍🏻

@ronaldclark1178 Год назад

A pull handle for tensioning the belt might help with starting. I had a mulcher set up like that. You had to completely release the tension on the belt to start the engine, then pull the belt tensioner handle until it tightened and cammed over. Good luck and Great video!

@DavidPozEnergy Год назад

Thanks. Maybe the bigger engine (6.5hp) will start easier?

@neverdemagain6043 5 месяцев назад

Oh wow!! I find old work out equipment and use the tube steel also. Tube steel is stupid crazy expensive right now.

@74HDJOE Год назад

Some people are giving you some ideas and advise that might be of help to your project. I'm pretty sure that you'll have all dialed in very soon, It looks good so far. 👍

@simonallan9941 7 месяцев назад

The 3hp should be ok at a continuous 6-7krpm, if you can put a smaller pulley on the engine and let it rev, and you can make them put out more power as well, change jet and exhaust, also air cleaner, especially in a cold environment it may want a richer mixture with a cold air intake 😉, great video thank you awesomely for sharing your experience and experiments, I wish I had that kind of equipment available for my off grid power supply

@mcook407 7 месяцев назад

LOL Oh come on David just rig the treadmill so when you run on it you generate, ya it's hard work BUT! Great Vid Sir, I just love the ingenuity... back to the show!

@Ski098 Год назад

That motor was crazy. Hard to start. Just need a bigger jerk on the rope. ;) (Sorry, couldn't resist. Great video!)

@drevil4454 Год назад

This is why I like youtube. Normal guys doing normal shit

@gregorytrenhed8318 Год назад

I have been watching your videos for so long and I gotta say your have truly grown in all aspects and I love how you use all the stuff on your mission

@DavidPozEnergy Год назад

Thank you, I appreciate it.

@dodgydruid Год назад

Interesting vid, I have a very old Italian Aspire engine which is a licenced Tecumseh from the 60-70's that I want to build a generator with, over here in the UK we only have 240v so a DC motor would be hard pushed to backfeed my ring main but I think I will go the alternator route and maybe make a supercapacitor overflow cell that I can charge lighter devices on the 5v 12v range. The engine was a genuine find in itself, never used just sat in a shops storeroom for decades and I bought it for £20 delivered too :D I converted my car to supercapacitor cell and it works extremely well esp as I have done the whole lighting with LED's, no incandescent anywhere on my little car, makes it very easy to start esp in cold and it is full charge in seconds from start.

@Richard-l1c3u 4 месяца назад

Failure is the best teacher and the other commenter is right a pulley change will make a huge difference a three horsepower engine can be used with a ratio change but also consider that the three horsepower with too much drag will use a lot more fuel so I would suggest both a ratio change and a horsepower increase

@redneckminer9164 Год назад

Consider using a PTO clutch on the motor side - that way you can start the engine, let it warm up, then turn on the PTO to engage the pulley connected to the DC motor.

@jameshancock Год назад

Rubber engine bushings will help

@calarndt Год назад

David smaller pulley on predator would increase the engine rpm. That would do two things. 1. It would allow the motor to run the generator at closer to the predators peak on the torque curve. 2. It would also lower the load on the predator at start time. I don't have a calculator handy but 3hp should be pretty close to all you need for an 1800 watt load.

@chrisdekock8864 Год назад

Great built my friend! I think that a PTO/direct drive will be a great addition, also a governor of sorts, like a selectable charging current to get to the sweet spot for your engine, to take advantage of the best of the power curve. I live on a sailboat, and im looking at doing a straight 175A alternator to a 6hp diesel engine for power generation in long winter nights and rainy cloudy weeks

@bumbarabun Год назад

"also a governor of sorts, like a selectable charging current to get to the sweet spot for your engine" MPTT charger if it is in proper mode should do that automatically.

@elmetbrown656 Год назад

Hi Dave I would leave the ribbed strap on and not a v-belt use the ribbed belt runs more easily and needs not as much energy as a V-Belt. Otherwise great work as always.

@Steelythestacker Год назад

Awesome work man. The only notes I would give is maybe a change in pulleys to adjust your torque a bit better and maybe a centrifical go-kart clutch to aid with starting. Other than that top notch work bud.

@raulorona7090 Год назад

As rule of a thumb you need 2.5 hp per 1 kw in a perfect set up, i make mine with a 5 hp engine with a 1 hp permanent magnet DC motor, RPM is 1800 runs at 90 VDC 10 amps. can take out the same 900 watts. after 5 hour running, motor begin to get hot is not designed for generate power but works. If you can find a Brigs and Straton engine got less vibration than predator engine and ad a flywheel for easy start and remove some vibration too.

@bitworkx6028 Год назад

Great repurpose idea. Just thought if you pick uo another treadmill that looks dead and wished you had a working treadmill, theres a battery compartment underneath the big display box ( bottom of the unit). The battery powers the display. Mine went dead and I luckily found the spot, changed the 9v battery and the unit worked again

@DavidPozEnergy Год назад

Good to know. Thanks.

@GeevyLic Год назад

David, think of it as a transmission when a guy goes up a hill and needs to shift down to pull the hill.it maybe easier to get a smaller pulley for the engine. Or a bigger pulley for the generator good luck!

@BigHeinen Год назад

That's actually a pretty brand of treadmill named NordicTrack. Also, the 3hp Predator motor is capable of only 2,206 watts of power (if it truly is a full 3hp??) before any mechanical losses so it is underpowered as you found out. Thanks for a great video!

@byronmill Год назад

Yes, they're not really a 3 horsepower engine. Peak torque is 3.5 lb/ft at 2500 rpm. Torque at max RPM of 3600 RPM is about 3.15 lb/ft, so about 2.16 horsepower under ideal conditions. Belt drive is considered to be .85 efficiency. I think the 800 to 850 watt output that he was seeing is limits of the engine, even if he tweaked the pulley ratio.

@cliffweatherbee6914 Год назад

This is awesome! Great for a backup battery generator!

@troy3456789 Год назад

Very interesting and seemingly right up my alley. I have the same kind of hydraulic crimpers you have. I also have a victron bluetooth shunt for my 100 amp hour battery. I just need about 30 more of those hundred amp hour lithium iron phosphate batteries and I'll be set for a minute.

@johnc7431 Год назад

I wrecked mine up with a 5.5 Honda engine put a Delco Remy alternator. Put a current switch on it. Just like you I started messing around. How I could charge my batteries the alternator works great

@aspendell209 Год назад

You should be able to get 1800 watts from 3 hp mechanical, even with high losses. I would try to play with pulley sizes until you can produce max rpms at peak of its power curve. Also, the first thing to go out on those treadmill motors is the shaft bearings. So you want to keep the belt only as tight as it won't slip.

@anthonyalleyne8724 Год назад

Great video! I did the same thing a few years ago. To take of the treadmill pulley, one must remove the fan first, tighten the shaft and turn the pulley either clockwise or anti clockwise, I can't remember! Its left hand thread!

@alvinhyman6838 Год назад

As a rule of thumb, on 120/240 VAC generators you need 2HP per 1000 watts . So using that scale you would need at least 5 HP to handle the 2.5 HP GENERATOR