How was the water wheel installation process?

The water wheel installation went smoothly, with perfect fitting and assembly.

What issue was identified and rectified during installation?

A gearing issue was identified and rectified by doubling the pulley size for increased RPM.

The sharp curve on the trough corner was fixed by the customer, resulting in an improved flow rate.

The variation in distance from the trough top to the water wheel was addressed by creating an angled shoot for water direction.

A dump load controller was developed to prevent the wheel from spinning excessively during grid down situations.

The water wheel installation process encountered various issues such as gearing problems, sharp curve adjustments, and distance variations, all of which were addressed through strategic modifications and improvements to enhance performance and efficiency.
Despite initial challenges and limitations with the alternator's capacity and power output, a shift to an 8 pole induction motor was deemed necessary due to mislabeling and inaccuracies in the generator's specifications, requiring significant modifications to various components for optimal functionality and power generation.

How was the water wheel installation process?
The water wheel installation went smoothly, with perfect fitting and assembly.
What issue was identified and rectified during installation?
A gearing issue was identified and rectified by doubling the pulley size for increased RPM.
How was the sharp curve on the trough corner fixed?
The sharp curve on the trough corner was fixed by the customer, resulting in an improved flow rate.
What was done to address the variation in distance from trough top to water wheel?
The variation in distance from the trough top to the water wheel was addressed by creating an angled shoot for water direction.
What was the solution for preventing the wheel from spinning excessively during grid down situations?
A dump load controller was developed to prevent the wheel from spinning excessively during grid down situations.

00:00

Water wheel installation went smoothly, with perfect fitting and assembly.
Gearing issue identified, rectified by doubling the pulley size for increased RPM.
Sharp curve on trough corner fixed by customer, resulting in improved flow rate.
Variation in distance from trough top to water wheel addressed by creating an angled shoot for water direction.
Development of a dump load controller for grid down situations to prevent wheel from spinning excessively.
Enclosure box prepared for the dump load controller, with specific components detailed.
Nozzle constructed to direct water flow onto the wheel, made of 316 stainless steel for durability.
Low voltage alternator replaced with a lower-winding version to prevent overheating at higher power outputs.
Testing conducted with increased water flow, reaching power output limits due to alternator constraints.
Alternator unable to sustain 2 kW output, reaching 80°C at 750 watts, highlighting limitations in power generation capacity.

20:48

To sustain 1.52 Kow consistently without overheating, a 4 kilow alternator is needed.
Leadings were added to aid in channeling water flow and prevent blockages.
Testing revealed the system could only handle up to 1,000 Watts before overheating.
Drainage was done to facilitate final adjustments and proper mounting of components.
The Spillway can manage a significant water volume.
Water flow was redirected to reduce splashing and align with the wheel's angle.
A dump controller was utilized to divert power to a heating element during grid failures.
Simulated grid failures confirmed the system's functionality in diverting power.
Issues with the alternator's capacity were discovered due to thin wire windings.
The alternator's wire thickness limits its output to a third of the stated capacity, leading to overheating and performance issues.

37:57

The generator in question was found to be unable to handle 2 KW without overheating due to the wire size being too small.
The actual power output of the generator was discovered to be much lower than the theoretical rated power, with the generator only able to output around 600 watts at 500 RPM.
Despite claims of selling a 5 KW alternator that could handle 2 KW, the supplier admitted that their products could only run at about a third of their stated capacity.
Due to the mislabeling and inaccuracies of the generators, the decision was made to switch to an 8 pole induction motor, requiring modifications to the mounting plate, guard, wiring, and pulley, as well as the addition of capacitors.