I Had To Rebuild The Waterwheel, The Driveshaft Snapped!
Kris Harbour Natural Building・20 minutes read
The water wheel experienced a catastrophic failure due to a failing shaft and gearbox, leading to a complete rebuild with a stronger, welding-free design. The rebuilt water wheel now has increased driving force and torque, ensuring durability and stability, with a reliable and secure final assembly.
Insights
- The catastrophic failure of the water wheel's shaft and gearbox led to a complete rebuild of the Hub, necessitating the installation of a larger, stronger shaft without welding for enhanced durability.
- The meticulous assembly process involved cutting off the old shaft, machining and fitting the new one with locking collars, and eliminating welding on the shaft to ensure a more robust and reliable water wheel system, resulting in increased driving force and torque.
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Recent questions
What caused the water wheel to stop suddenly?
Failing shaft and gearbox led to halt.
How was the rebuilt water wheel improved?
New design with larger, stronger shaft for durability.
What was the testing process for the repaired water wheel?
Tested with water flow, reaching 5 L/second initially.
How has the rebuilt water wheel been performing?
Producing 1,050 Watts currently, monitored for steady performance.
What advice was given to the customer regarding running the water wheel?
Advised to run below a kilowatt initially for safety.
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Summary
00:00
Water Wheel Rebuild Enhances Durability and Stability
- The water wheel experienced a major catastrophe due to a failing shaft and gearbox, leading to a sudden halt.
- The customer sent a video showing the wobbling gearbox and the failing sensor, prompting immediate action.
- The shaft sheared off completely during operation, necessitating a complete rebuild of the Hub.
- The welding on the shaft caused it to deteriorate, leading to its failure, requiring a stronger rebuild.
- The new Hub was machined and assembled with a larger, stronger shaft without welding for better durability.
- The process involved cutting off the old shaft, machining the new one, and fitting it with locking collars for stability.
- The assembly was challenging, requiring a sledgehammer to fit the components due to a tight friction fit.
- The rebuilt water wheel now has increased driving force and torque, ensuring durability and stability.
- The process involved meticulous alignment, welding, and bolting for a secure and reliable final assembly.
- The new design eliminates welding on the shaft, ensuring a more robust and reliable water wheel system.
20:45
Water Wheel Upgrade Increases Power Output
- The water wheel was repaired with four 12.9 cap head bolts, welded all around, and updated with a new 65mm shaft, bigger bearings, hub locking collars, and a larger gearbox.
- The wheel was tested with water flow, reaching a flow rate of about 5 L/second initially, with full flow expected to be around 100-120 L. The setup was tightened to specification to ensure reliability.
- The wheel has been running for about two months, producing 1,050 Watts currently, with a total of 9.2 kwatt hours since midnight. It has been monitored for output fluctuations and has shown steady performance.
- The wheel's output history was detailed, showing variations due to maintenance, low river levels, and blockages, with the customer advised to run it below a kilowatt initially. The system has been certified by an electrician for safety and reliability.
