Category: Hybrid

Bench Testing

It is easy to see the rpm variation potential now that slip is eliminated between the drill and the PIE’s wheel. For testing purposes, I have braced the drill with a piece of metal so it wouldn’t keep pulling it back and causing speed variations since I was not holding it steady enough.

As I continue the build, I still have not decided on a motor to power it. I do not want to commit to any particular motor design or speed, before doing some initial testing. There is still more work to do before I get to that point, at which time I will post those results here as well.

I am certain of is that if the PIE 2.0 becomes much more powerful, the whole unit will need a redesign so that it does not tear itself apart!!

I am also considering installing some very light weight springs to keep the weights from folding inward when it is not running. When that happens, the assembly can jam and not turn, it is as close to a “backfire” as the PIE 2.0 can have. The springs need to weak enough not to affect operation, but strong enough to do the job. I made it work with rubber bands, but they certainly won’t last long. It is something to think about.

Addendum 6/11/2020: As I was thinking about the possibility of adding some sort of spring (rubber bands work well) I noticed a spring clamp in my toolbox. EUREKA!! That is most likely the answer, a torsion spring! Like a mouse trap spring, the torsion type spring might be exactly what I need to keep it from “stalling on startup” without applying enough force to change how the PIE 2.0 works!!!

Bench Testing Chain Drive with Drill as Power Source

I finally got my sprockets for the chain drive! They are surplus so there are nicks and dings, but nothing a file won’t easily fix. They have an “unfinished” one-inch (25 mm) hole, that puts the hole slightly undersized, but that actually worked out in my favor for use on the jack shaft as it made for a nice press fit on the 1” section of shaft. I then welded the sprocket into place on the shaft to make it a permanent install.

I used a plasma cutter to open the 1” holes up on the sprockets being used on the wheels, that way there is no need for spacers to mount them on the axles. Cutting the hole open like that is ugly, but I don’t really care, as it cannot be seen once it is installed.

I put it together enough to see the chain drive work with a cordless drill running it up to approximately 1500 RPMs. I still need the parts bolted to the plank base so that nothing can shift position with the weights installed.

I believe that I will wait to finish the drive assembly with a motor until I can see how much power it is going to take to make it run, and at what RPM. I have several large electric drills that I can use to do those tests if necessary.

Truing a Sprocket on a Wheel Assembly, Getting Ready to Weld

Bench Testing Chain Drive with Drill as Power Source  

Dual Weight PIE Bench Test & Making the Drive Jackshaft

Two days ago, as I was finishing up for the day, I decided to put both new weights on a single flexplate assembly at the same time. I really did this as a way to see the action and make observations of any interference between them. I was pleasantly surprised when the interaction appeared to be complimentary in nature.

I was so pleased with the interaction that I decided to “spin” it up with the cordless drill. The amount of power being transmitted to the bench was remarkable, and because the flexplate was “balanced” out with the second planet assembly, I was able to run it at a somewhat higher speed without further modification.

I observed the weights each contacting a stop (one inner, one outer) at virtually the same time and producing complimentary pulses. I was so pleased that I immediately cobbled together a way to hold my phone and video this (the video is below and on YouTube).

Powered Dual Weight Bench Test

Now I am getting ready to put the chain drive on it, although I am no longer sure it is necessary to have a positive non-slip drive. I am including some pictures of the jackshaft being made at a local home-garage machine shop. I didn’t have any keyways cut into it, but I can always take it back for that if necessary. The dimensions are ½” up to 17mm up to 1” and back down to 17mm.

Cost was negligible for this because I supplied the metal to a home machine shop (along with beer) on a Saturday. Normal cost for this at a local machine shop would have been around 35 to 45 USD according to a couple of calls made, but many machinists would do this on their lunch hour at work for about $20.

 

Jackshaft in Lathe & Finished

The plan is to weld a sprocket onto the 1” diameter section of the shaft, then bearings will be mounted on the 17mm sections and then the ½” diameter end will be used for the electric motor’s connection.

According to the surplus company I ordered the sprockets from, I should have them in about 3 days…

Newest Weight Ready for Testing

Building the revised PIE, version 2.0, is well under way. There are two weights are virtually ready for testing. The gears are looking as good as they ever will, and the base has been partially modified to accommodate the revisions in the configuration.

I have decided that the drive system will be using #40 roller chain & sprockets. The sprockets and chain are available at a very reasonable price from surplussupply.com. It is too bad that they do not have spur gears to use for the sun & planet gears as well. Regardless, I am getting as much done as feasible while I wait for the sprockets arrive (I already have chain).

 I am planning to use a jackshaft, of sorts, to drive the chain. The inexpensive and plentiful components already sourced and obtained will comprise a portion of the jackshaft assembly. I am having a custom shaft machined upon which to fasten the sprocket.

A custom shaft would be unnecessary if the shaft, sprocket and available bearings were all the same diameter, but weighing the option of sourcing more components vs. those already obtained and having one custom component made I choose the latter. A local machine shop would make the shaft for between $25 and $50 US, while pillow block bearings would be that price for each one. As previously stated, the objective is a simple, replicable drive, that is also safe and affordable.

Testing the Action of the Second New Weight

 

Second New Weight Getting Painted

First:

The PIE 2.0 project has commenced.  As could be seen in the pictures contained in my last post, a new weight is being developed for PIE 2.0. I plan on using the same design for the planetary gear sets because I they are simple and robust. I was not sure about the flexplates, but since they are already prepared for the purpose, I will use them until a reason to change presents itself. Some parts are being reused (from the 4-wheel unit) and/or repurposed. There are still many questions to be answered and most of them need to be put on the work bench in order to find the answer.

We know that computer models and all the advanced trigonometric formulas in the world are useless unless there is a way to put them to work. The differences between types of drives can be discussed, compared & argued but the proof is in the workshop. Sooooooo… I need to make something PERFECTLY clear.

The fact is, this damn thing works!

Setting up for bench Testing

Setting up for bench Testing

Second:

The Problem with Physics is that Some Science is Not Allowed:

Science is: The observation, identification, description, experimental investigation, and theoretical explanation of phenomena.

Physics is: The science of matter and energy and of interactions between the two.

Our currently taught physics does not allow for certain outcomes, and any drive system that does not push against anything for propulsion is one of those outcomes not being allowed for.

Along with physics departments worldwide, NASA currently discounts this type of tech as fantasy. Yet NASA is currently using reactionless propulsion to position/reposition satellites in Earth’s orbit.

Countless scientists have witnessed a very early version of this system operate with greater efficiency than wheel driven, jet, propeller, or rocket driven forms of propulsion, yet they turn right around and state unequivocally that it is impossible and absolutely cannot work…Ever! 

Many witnesses will deny that they ever saw, or that there ever was, a working demo.

People’s lives have been ruined because they built a working device and tried to sell it to big business and/or governments.

Science teachers worldwide are told that if they teach this as a possibility, they will be fired. The only way this can be included in a curriculum is by “proving” it doesn’t work.

It seems that the ONLY ALLOWABLE outcome has been negative or no.

Since this Grassroots project flies in the face of all of that, I continue to publish ALL information regarding the PIE system (1.0, 2.0 and future versions) and as stated earlier, the inconvenient fact is that this damn thing works!

I hesitate to say that I am working to change the paradigm, but it works and it is repeatable.

This knowledge NEEDS to go public, needs to be peer reviewed, and needs to be put to use helping people everywhere travel more efficiently.

Third:

PIE 2.0 To-Do List (Subject to Change of Course):

1- Set up outer stops for the new pendulum weights

2- Enhance bearings on all rotating assemblies (Doubles?)

3- Strengthen framework to withstand higher power output

4- Higher speed & strength motor

5- Synchronous drive system (Roller chain, T-belt?)

6- Consider “stacking” flexplates rather than side-by-side positioning to reduce footprint

7- Consider sourcing off-the-shelf parts for future versions, kits, etc.

Fourth:

A personal note:

As I am writing this, I want to thank everyone for watching my videos and reading my words.

I need to remind everyone following along that I am funding this completely out of my own pocket and then sharing it freely. I am not accepting donations nor am I selling anything for funding or profit.

There may be a saleable product in the future, however, ALL of the info in my personal journal & subsequent public blog are still going to be free as long as I have a say.

Perhaps, eventually, kits might be made available. I can imagine a kit to add hybrid capability to a vehicle for about the price of a go-kart.

 Right now, I want to share this with everyone, worldwide. I would hope others would see how simple this is to build a PIE as well.

Volume 2 (PIE2.0)…

The rework of many unused parts that are left over from PIE1.0 has begun, along with some newly fabricated pieces for the new unit. Planning for this began about the same time that the first successful demo pulsed its way across multiple work benches.

From the time that first unit moved on its own I have wanted to build a better unit, capable of higher RPMs and running a heavier pendulum weight. Digressing to, and remembering, the 1970s VHS video of Brandson Roy Thornson’s drive pushing a canoe around an Olympic sized swimming pool, that unit had 4 rotating discs (2 CW rotation, 2 CCW rotation) and each had a 5-pound pendulum weight.

PIE 2.0 is going to start out with weights that are around 4.7-pounds. They will not be using any counter-rotating assemblies unless it is deemed absolutely necessary. Yet to be determined is to the number of rotating assemblies, the power source, and speed of rotation (RPMs).

I have about 20 to 25 pictures of various parts, pieces, tools & assorted “junk” waiting to be put to use. Since some find that interesting, I will put some of the pics in this the blog, but will not include them in my personal journal documenting this project.

Base Part in Primer

Chop Saw

Small Drill Press

Spare Motor

Spare Motor

Spare Parts

Lengthened Planet Gear Axle – Revised To Be Used As Stop

PIE 2.0 Weight

Base Part

Planet Gear Needing Re-Work

Planet Gear With Long Pivot Bolt

2 Flexplates & Assorted Junk

Mocking up PIE 2.0

Mocking up PIE 2.0

Mocking up PIE 2.0

Pieces & Parts

Weighing As We Go

Digital Scale is More Accurate

Setting Up Revised Stop On Planet Gear

What a Mess!