Homemade manual generator for charging your phone
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Homemade manual generator, how to make it?
How to make a camping generator for charging a mobile phone using a hand trainer that is popular today. For the experiment we took an inexpensive plastic model. The structure of the simulator is very simple, two halves of the body and a rotor. The rotor is the most important and interesting part in this device; it can spin over 10,000 rpm. On the rotor, along its circumference, you need to install neodymium magnets. You can use the original rotor, but it would be better if you made it metal and more massive.
Now, for it to become a full-fledged electricity generator, you need to add a small inductor coil to it, literally 150-200 turns of 0.2 wire will be enough and it should be placed strictly above the flying magnets. To do this, we will fix it in the place where the cover is located, the cover of the hole where the meter is attached. To do this, I made a special metal plug with a core, where I place a small coil, leading the wires out through the side hole. These wires will need to be connected to a separate wire that you will connect to the load. Continue watching the video...
Watch video instructions for creating a homemade hand generator on the video training portal, Video Teacher. Enjoy watching and good luck to you!
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Now it's hard to imagine my life without mobile phone or tablet. But sometimes there are times when you need to make a call or go online, but the gadget is dead and there is no outlet nearby. In this situation, a compact hand generator helps me out.
Step-by-step production of a generator for a mobile
I borrowed a dynamo mechanism and a charging unit from an old mechanical flashlight (photo 1). I removed all internal parts from the plastic box of the non-working modem. On one of the walls of the box, on the inside, I attached a dynamo mechanism with a heat gun (photo 2), drilled a hole opposite its rod and attached a handle to it from the outside (photo 3)
In the second part of the case I fixed two rechargeable batteries, a charging unit and a USB connector with a board (photo 4). I connected all the elements according to the diagram (see figure on) (according to the diagram, batteries are connected instead of a lamp) and connected the charging unit to the dynamo mechanism. Additionally, I attached a toggle switch to the end of the case next to the USB connector (photo 4. p. 1), connected it to the USB board and the contacts of the charging unit. It serves as a switch: in one position, gadgets can be charged manually, and in the second, with batteries pre-charged by the same device.
Carefully reassembled the case in reverse order. To charge, I connect my phone or tablet to the device and start turning the handle. A compact generator has more than once helped me and my family out on camping trips and at the dacha, where there are often power outages.
One day, I received as a gift from a friend two megaohmmeters that were not working - both had damaged measuring heads.
When opening one of them, it was discovered that in addition to two boards with radio components and a measuring head, the device contains a dynamo alternating current with manual drive.
The generator turned out to be in working condition - when rotating not too fast (about 40-50 rpm), it produced a voltage of about 25V (without load).
Further disassembly of the unit showed that it is a fairly high-quality single-phase electric machine with a permanent magnet rotor.
The only drawback is the plastic housing and bushings (I would like bearings) in the places where the rotor is installed. It didn’t take long to find a solution to where to use this unit - conducting experiments on charging mobile devices in the field. Progressive Chinese have long released a similar device for sale and are selling it in their well-known store Dilextream.
First, it was necessary to rectify and stabilize the generator output voltage. The 2-amp coped with the first task perfectly. diode bridge. As a stabilizer, it was decided to use the well-known circuit with the integrated stabilizer K142EN12A (LM317). A typical connection diagram is shown in the figure.
The choice of this stabilizer is not accidental. For emergency charging of a mobile phone, a voltage of 4.5-5.5 V at a current of 100 mA is sufficient, and it would seem logical to use the K142EN5 stabilizer. But it's not that simple. Since the generator produces more than 10V even with slow rotation, it was decided to use a stabilizer whose input voltage can range from 8 to 35V - the KR142EN5A stabilizer would simply overheat due to the high input voltage. So, the stabilizer is assembled and it’s time for the first load tests.
For these purposes, I used a 26V 230mA incandescent lamp and obtained a fairly bright and even glow of the filament at the nominal turns of the handle of this improvised dynamo machine. Next, it was decided to use a five-watt resistor as a load. During these tests and at maximum speed rotation of the rotor (spinned it as quickly as I could!) it was found that at a certain moment (apparently when the stator winding is oversaturated) the generator goes into current generation mode. Finally it's time to test the battery charge mobile device. Dachny cellular telephone Samsung GT-E1081T was the best choice for these purposes - if something breaks, it won’t be such a shame. So, the phone battery was completely discharged, everything was ready for the experiment. By connecting the device to an improvised charger, began to rotate the generator handle without making almost any effort. After about forty seconds the phone turned on and showed a charge indication. After turning the speaker knob for about two or three more minutes, I unplugged the phone from charging and tried to call - it worked, the call went through.
Conclusions. The use of such a device during a hike is very justified - in case of an emergency, you can always dial the desired emergency service, regardless of weather conditions (see application solar panels), although it is impossible to fully charge the battery of a mobile device with this generator (although there may be someone more patient who can turn the handle until the battery is fully charged!). In general, on the basis of such a spare part from a megaohmmeter, you can assemble many more useful structures. For example, emergency lighting in a basement, closet or living room, or the use of a machine dynamo without an overdrive gear unit as a mini-generator in experiments using wind energy, and so on—there can be a great many variations on this theme. Good luck with your experiments and designs! Author: Eletrodych.
In matters of autonomous power supply in the absence of electricity or interruptions in supply, you can use so-called alternative sources of electricity. Such as wind power plants, hydro, and gasoline-diesel generators. But all these sources of electricity have their drawbacks. Because they require energy from outside to convert it into electricity.A wind generator needs wind, which does not blow constantly, and solar panels need sun, which does not come for weeks, especially in winter and in cloudy weather. Generators powered by internal combustion engines require fuel, which is only becoming more expensive, making them unprofitable, as well as Maintenance etc., makes them an expensive toy, or an emergency source for a short time.
I want to consider this option. For example, a manual generator that runs on human muscle power. Besides the fact that you have to turn it yourself, it has a number of advantages. It does not depend on weather conditions (wind, sun), it is also mobile, easy to handle, and can be used anywhere. The smallest representatives and the most famous are Chinese hand-held dynamo chargers for small electronics. But such small “dynamics” are only suitable for emergency charging, and using them for constant energy production is extremely inconvenient.
Firstly, they provide too little energy, and to charge a simple phone or small flashlight you need to turn them for hours. And if electricity is needed every day, then such devices, firstly, will not withstand and will quickly fail from constant loads, since they are made of plastic and are not designed for a long service life. And it’s simply not advisable for a person to twist this thing for several hours a day in order to charge a mobile phone and other electronics, and after 15 minutes of twisting, his hands simply get tired from monotonous movements.
The solution may be to have a larger manual generator, so that it produces a much larger current that can be used to charge a large battery. And this battery can be used to power and charge portable electronics. That is, a large generator can charge or recharge a capacious battery, which, for example, will be equipped with a car cigarette lighter socket. And after some time, use this energy by connecting various electronics through the cigarette lighter socket.
And when the battery runs out, charge it again. This solution will allow you to constantly use energy and at the same time turn on the generator only when the buffer battery runs out of charge, and a large battery can last for weeks or more. It depends on how you use electricity. I think it is clear that such a source is considered only to provide the minimum human energy needs, such as charging portable electronics, and maximizing the use of a laptop.
For these purposes, for example, this ready-made option may be suitable. Military hand-held generators, they are precisely designed to generate electricity in any conditions and in any place. The power of such generators is from 3 watts to 70 watts. There are many models with different characteristics, and more modern analogues also have many outputs adapted not only for charging large batteries, but also for charging portable equipment (USB, 12V, 19V outputs)
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They can also be equipped with any necessary additional inputs and outputs. The advantage of such large generators in comparison with Chinese speakers is obvious. Such a generator is quite powerful and produces up to 100 watts of energy in a couple of hours, while small generators produce only 2-3 watts. This means that they can charge a large battery, for example, like on a computer UPS, and then use the energy.
But lead-acid batteries do not like fast charging and quickly fail. The optimal charge mode is about 10% of the battery capacity. What I mean is that you shouldn’t charge lead-acid batteries with increased current, but how can you reduce the charging time if the battery needs to be charged for 10 hours, because you can’t turn it that much.
There are two options here: use lithium-ion batteries, which can be charged with high currents, but are currently capacious lithium-ion batteries almost not available for sale. Or NI-HM batteries of the new generation, which can be charged with high currents up to half the capacity of the batteries themselves. The only thing is to monitor the temperature of the batteries, as they get very hot at high charging currents. And you need to make sure that the temperature does not rise above 70 degrees Celsius. Or use large lead-acid batteries with a 10% charge capacity.
For example, if you take a military generator, as shown in the figure above, and spin it as written in the instructions, that is, 60 rpm, then, depending on the model, it will produce a nominal voltage, for example, 50 watts. It turns out that the generator will produce about 4A of current, which means that if you use a lead-acid battery for charging, then you need a capacity of about 40A. A car battery will do, but less is possible. If you use a small battery, you need to make sure that the current does not go beyond the design parameters. For example, for a 10-amp battery the charging current is 1A, but for a short time it can be up to 2A.
If we consider something really powerful, like a high-power home or camping power station. You can also use a practically ready-made option, such as a bicycle and a bicycle motor-wheel. Now, with the development of electric transport, a large selection of kits for converting bicycles to electric power has appeared on sale.
A ready-made wheel motor is used as a motor. This wheel motor is also an excellent low-speed high-power generator. And it can produce, for example, a wheel motor with a power of 350 watts; in generator mode at the same speed it can produce up to 300 watts of energy. Below in the photo is an example of a finished power station based on a bicycle with a motor-wheel. 
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As the basis for such a power station, you can use either a ready-made bicycle or just a frame with pedals, which can be installed permanently. Also, a wheel motor is needed without any additional bicycle “principles”. And the generator itself is much cheaper than a bike conversion kit. Prices for motor wheels start at 3,500 rubles, but you can find cheaper ones, especially second-hand. All adaptation to a generator consists of connecting the motor as a generator.
The wheel motor is a three-phase low-speed permanent magnet motor that produces alternating voltage in generator mode. To rectify, convert current from alternating to direct, you need to make a simple rectifier using diodes. And also to monitor the battery charge you need to connect an ammeter and a voltmeter. Below is an approximate diagram of connecting the battery for charging.
When using control devices when charging, it is good to navigate. For example, when charging a car battery, you need to keep the current no higher than 6 amperes, although up to 10 amperes are possible for a short time. And the generator itself can output up to 20A. Using a voltmeter you can check the battery charge level. If the voltage at the terminals during charging rises above 14.5 volts, it means the battery has been recharged; you should also not lower the battery discharge below 11 volts, this also affects the resource.
In order not to charge a dead battery for 10 hours, you can do this. When the battery runs out a little, just recharge it, although this should be done more often, but in terms of time it will be much less, 1-2 hours. When using such a power station, you can charge portable electronics and connect LED lighting through the cigarette lighter socket in the absence of electricity. And when used economically, it is enough to spin such a shaft generator once a week, since in 1 hour you can generate up to 100 watts of energy.