Pump'n Power Handcar Generator instructions
|Flock House - Engr215 Student Projects|
|EcoDermis - Skin for the Win - Poly Pod - Geared-Up From the Feet-Up - Biopod - Hyper Visible Power Meter - Handcar Generator - flockhouse.org|
The following is a brief overview of the steps the create your own Pump'n Power generator. Given the complexity of the design for this project, the finer details of the project are left to the builder to specify. Such details include the placement of supports, placement of the generator mounting point and plate, length of the pump lever, and method of attachment at each point.
To build the frame you will need two bicycles. At least one should have functionally rotating pedals, wheels, and crank at the bottom bracket. The other bicycle need only contain a frame and handlebars; it will be referred to as the "scrap bicycle" and used as framing material. For the frame, most of the support pieces are welded to the main frame. The rear support is mounted to the rear axle position thereby two rear bicycle frame components are mounted to the same rear axle.
Pump Lever and Crank Shaft
The pump lever is made up of steel square bar stock, a front bicycle wheel hub with quick release axle, two handle bars from the two bicycles, and the pedal that was removed earlier. The crank shaft is made up of round bar stock with an internal diameter that is the same as the diameter of the pedal material removed from the crank so that it can be inserted into the round bar and secured.
The generator is mounted below, and chained into, the rear cassette.
|Step 1: Mount generator to bottom plate.|
|Step 2: Chain in generator.|
|Wiring diagram. (Photo by _______)||Step 1: Wiring diagram.|
|Charge controller installed. (Photo by _______)||Step 2: Mount the charge controller onto the rear part of the frame near the generator.|
|Blocking diode installed. (Photo by _______)||Step 3: Wire the blocking diode inline with the battery.|
|Fuse installed. (Photo by _______)||Step 4: Wire a fuse into the system to prevent an overflow of current into the charge controller.|
|Rectifier installed. (Photo by _______)||Step 5: Wire a rectifier to both ends of the generator to ensure no matter which what the generator rotates, current polarity remains the same.|
|Battery connected. (Photo by _______)||Step 6: Wire in the battery.|