Powering An Old Mill - 1.5 Kw Lake District Overshot Waterwheel Project Part 2

Kris Harbour Natural Building・2 minutes read

The text describes the detailed process of constructing and testing a water wheel for power generation, highlighting the careful planning and adjustments made to optimize efficiency and safety. By making adjustments to control settings and flow rates, the wheel's speed was slowed down to prevent energy wastage and overheating, ultimately leading to more efficient power generation.

Insights

  • The construction of the water wheel involved a collaborative effort between the creator, the owner, and friends, with meticulous attention to detail in assembling the components and ensuring safety measures were in place.
  • Testing and optimization of the water wheel for power generation included controlling water flow, adjusting settings to manage wheel speed, and addressing energy wastage issues, ultimately leading to a power output of 950 Watts. Further adjustments, such as modifying the controller settings and installing a larger pulley, are planned to enhance efficiency and prevent energy wastage.

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Recent questions

  • How was the water wheel constructed?

    The water wheel was built on-site by the customer, family, and friends, alongside the creator during the wheel's construction process. Site work involved creating pads, foundations, and temporary templates for layout planning. Concrete was poured based on scale models, with locally made upright stanions for support. The trough was assembled in pieces, then reassembled in its final location due to its weight. The spillway was worked on to control water flow, completing the dam for the mill pond.

  • What adjustments were made to the water wheel?

    The water wheel was designed by the creator, with adjustments and fabrication done by the owner and friends. Wheel assembly included fitting spokes, outer ring pieces, and buckets with attention to detail. Rubber seals were placed between buckets for a secure fit, and a gearbox was mounted. Temporary wiring and a substantial Earth connection were set up for safety and speed control.

  • How were tests conducted on the water wheel?

    Tests were done to ensure functionality and safety before connecting to the grid with an electrician's help. The process involved filling the pond slowly to spillway level, controlling water flow using boards, and setting up temporary wiring with a big Earth connection. Water was allowed to run over the wheel for voltage testing at freewheeling speed, with a flow control mechanism managing speed.

  • What adjustments were made to optimize power generation?

    Adjustments were made to optimize power generation, including tweaking flow rate and addressing energy losses. The wheel was connected to a shed for power output testing, reaching 950 Watts at a specific flow rate. Further adjustments were planned to improve efficiency, such as addressing splashing and corner issues for better performance.

  • How was energy wastage prevented in the water wheel?

    To prevent energy wastage and overheating, a larger pulley was needed to increase the alternator's speed while slowing down the wheel. This ensured a more efficient power generation process. Adjustments were made to the controller settings to slow down the wheel speed and increase the flow rate for proper filling, reducing energy wastage and optimizing efficiency.

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Summary

00:00

Community-built water wheel for sustainable energy.

  • The water wheel was constructed on-site by the customer, family, and friends while the creator was building the wheel itself.
  • The site work included creating pads for the water wheel, foundations for the trough, and constructing temporary templates to plan the layout.
  • Concrete was poured based on scale models, with locally made upright stanions supporting the structure.
  • The trough was constructed in pieces, then assembled in an accessible position before being disassembled and reassembled in its final location due to its weight.
  • Work was done on the spillway to control water flow around the wheel and complete the dam holding water in the mill pond.
  • The water wheel was designed by the creator, with the owner and friends making adjustments and fabricating necessary components.
  • The wheel assembly involved fitting spokes, outer ring pieces, and buckets, with careful attention to detail to avoid damaging the paint.
  • Rubber seals were placed between buckets for a secure fit, and a gearbox was mounted to the structure.
  • Temporary wiring and a substantial Earth connection were set up to control the wheel's speed and prevent accidents.
  • Tests were conducted to ensure the wheel's functionality and safety before connecting it to the grid with the assistance of a qualified electrician.

24:12

Water wheel setup for power generation testing

  • The text describes setting up a water wheel for testing and power generation.
  • The process involves filling a pond slowly to the spillway level and controlling water flow using boards.
  • Temporary wiring is set up with a big Earth connection for safety.
  • Water is gradually allowed to run over the wheel to test voltages at freewheeling speed.
  • A flow control mechanism is used to manage the wheel's speed and prevent dangerous voltage levels.
  • The wheel is observed to spin too quickly during freewheeling tests, leading to energy wastage.
  • After shutting off the wheel, a load is wired onto it for power generation testing.
  • Adjustments are made to optimize power generation, including tweaking the flow rate and addressing energy losses.
  • The wheel is connected to a shed for power output testing, reaching 950 Watts at a certain flow rate.
  • Further adjustments are planned to improve efficiency, including addressing splashing and corner issues.

41:49

Efficient Water Filling and Power Generation Optimization

  • The issue with the water flow and bucket filling is due to the bucket fill angle and the wheel spinning too fast, leading to splashing. Adjustments need to be made to the controller settings to slow down the wheel speed and increase the flow rate for proper filling.
  • By accessing the special settings on the controller, the voltage was reduced to 100 volts to slow down the wheel speed, allowing for more efficient water filling. Further adjustments will be made to find the most efficient speed.
  • To prevent energy wastage and overheating of the alternator, a larger pulley is needed to increase the alternator's speed while slowing down the wheel, ensuring a more efficient power generation process. Final modifications will be made after the electrician installs permanent cables.
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