DIY generator. Petrol 25kW 220V AC + 400V DC. Part 1
Friends, hello everyone. Whoever follows our channel knows that for almost the whole year we have been creating a powerful electric buggy. And in the fall, the first combat tests were carried out. If anyone is interested, you can read Homemade Electrobuggy here.
In parallel with the buggy, we started a second project. This is a power generator project called Move & Move.
What are his main tasks:
1) Work as an emergency generator for a country house. AC operation.
2) Work as a charger for electric vehicles with the ability to charge on the go. Direct current operation.
2-3 times a year, almost any owner of an electric car has a need for long trips. It is very convenient to have such a generator on a trolley (trailer) and go anywhere without thinking about charging stations. Tesla owners will find it very useful for long trips to take such a generator, for example, for rent. Unlike conventional generators, it will allow you to immediately deliver a constant current to greatly speed up charging.
3) Experiments with high voltage of the order of a million volts in remote uninhabited places. Tesla coil.
4) Gaining experience in the development of high power generators.
To produce an electric current, we need to convert one type of energy into another.
It is based on Nissan’s HR12DE internal combustion engine. He met several search criteria at once. Since in the future it is planned to install this do-it-yourself generator on a trolley, the engine had to be light and compact. At the same time, it should have had low fuel consumption throughout the entire rev range. And lastly, the engine itself should have been with a low price of up to 20 thousand rubles (at the end of 2021).
The Nissan HR12DE internal combustion engine was released in 2010 by Nissan Motors. Has 3 cylinders and 12 valves. The volume of this engine is 1.2 liters. In the piston system, the piston diameter is 78 millimeters and its stroke is 83.6 millimeters. Fuel injection system installed Double Over Head Camshaft (DOHC). Such a system predetermines the installation of two camshafts in the cylinder head (cylinder head). Such engine manufacturing technologies made it possible to achieve a fairly strong reduction in noise and obtain a power of 79 horsepower, as well as a torque of 108 Nm. The engine is quite lightweight: 60 kilograms (bare engine weight).
Volume, cubic cm
Gas distribution system
DOHC, 12-valve, 2 camshaft
Power, h.p. (kW) at rpm
79 (58) / 6000
Torque, kg * m (N * m) at rpm
106 (11) / 4400
3-cylinder, 12-valve, DOHC, liquid-cooled
Gasoline Regular (AI-92, AI-95)
Fuel consumption (mixed mode)
Further, the conversion of mechanical energy into electrical energy occurs by rotation through the flywheel of the generator from the box of the electric version of the Nissan Note. The engine itself had to be slightly modified so that the bell of the box stood up as it should. Moreover, the box contains 2 electric motors. One power and the second auxiliary 50 kW (pictured on the right). Here we need an auxiliary one. The power unit will be dismantled and put on a shelf waiting in the wings.
At the output, the generator outputs 3 phases of high frequency alternating current of the order of 1 kHz, depending on the revolutions at which the internal combustion engine came out.
The generator itself fits into the gearbox housing.
Further, the alternating high-frequency voltage is supplied to the rectifier unit. IGBT module from Toyota Aqua with power up to 50 kW was used as a rectifier module.
After that, the rectified voltage is supplied to the DC-DC converter also from Toyota Aqua with a power of 27 kW.
The converter itself had to be greatly altered. At the output we have a well-stabilized voltage of 400V DC. And those outputs that were previously used to connect electric motors can now be used to connect a 220V 50 Hz load.
More detailed information about the generator with your own hands can be viewed on our Youtube channel “Engineers’ Time”