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Motorbike Stator Coil

06/21/2011 6:51 AM

hi guys,

I'm an electrical engineer by trade and I'm trying to install some lights on my motorbike... I have chosen low power consumption LED lights (1W headlight and 1W tail light), as the stator coil which powers the spark plug is very small... I know it can spare 2W for 2 lights..

The stator coil spits out an AC voltage obviously as it's mechanically powered from the motorbike crank.... I need to convert this to DC get about .15A out for the lights... the bike shops do sell these converters, they call them LED regulators... but they're about $300 a pop, and I know they're charging that much because of the name..

I'm pretty sure I can either make a regulator or buy something equivelant... any thoughts? Does anyone know what they might be called at local electronic hobby shops etc? LED regulator does not return much in google..

Here's the wiring schematic for the lights, http://www.smallcoilrewinds.com.au/file_transfer/pdfs/LED-LIGHT-MK4-5.pdf

ignore the horn and colours..

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#1

Re: Motorbike stator coil

06/21/2011 7:03 AM

Why not take it straight from the battery? (Asuming they are 12volt!!)

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#3
In reply to #1

Re: Motorbike stator coil

06/21/2011 7:15 AM

there is no battery, all lights will run directly off the stator coil

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#2

Re: Motorbike stator coil

06/21/2011 7:10 AM

"The stator coil spits out an AC voltage obviously as it's mechanically powered from the motorbike crank.... I need to convert this to DC"

I'd think that any competent electrical engineer, electrical technician, electrician, electrician's helper, cable TV installer, motorcycle mechanic, motorcycle mechanics helper, hobby shop clerk, hobby shop janitor, garbage truck driver and just about any teenage boy on the planet could rectify this dilemma for you.

BTW, leave the training wheels on the bike.

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#4
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Re: Motorbike stator coil

06/21/2011 7:22 AM

yeah it's been many years since I studied, has anyone ever made a rectifier/regulator ?

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#5
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Re: Motorbike stator coil

06/21/2011 7:54 AM

well I've just been refreshing myself on electronics, and I think I've come up with a design which will work, I plan to solder up a full bridge rectifier with capacitor in parallel with resistor to have a near smooth DC voltage output, then feed this through a voltage regulator and hopefully obtain a constant 12V out for my lights!

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#6
In reply to #2

Re: Motorbike stator coil

06/21/2011 8:13 AM

Good one! Lyn.

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#7

Re: Motorbike stator coil

06/21/2011 9:10 AM

Have you stuck a meter on the output to check the volts (and to check that it's AC)?

What did it read?

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#8

Re: Motorbike Stator Coil

06/21/2011 9:51 AM

LEDs and a current limiting resistor will probably work fine.
You shouldn't need a rectifier... the clue is in the name Light Emiting DIODES.
Ok I havn't tried it and I don't know the breakdown voltage of the LEDs in question, but 5 minutes of experimentation is worth 2 hours of googling.
You only really ohms law and some leds to play with.
Failing that, just about any old bridge rectifier should do the job I'd think, but again... experimenting is the key and don't ground any wires, keep the led circuit completely separate from everything else it will simplify it.
I reserve the right to be completely wrong here... it's a long time since I rewired my old Lambretta, Mamma mia, she's a long a gone to scooter heaven
Del

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#9

Re: Motorbike Stator Coil

06/21/2011 11:25 AM

Do bear in mind that any modifications to the vehicle must be reported to the vehicle's insurers lest a different premium is payable for the cover for a modified vehicle.

Also, in the UK, all modifications away from the original manufacturer's specification must comply with the annual MoT test requirements for the vehicle to remain on UK roads. There may be similar requirements in other countries.

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#10

Re: Motorbike Stator Coil

06/21/2011 12:23 PM

So, just headlight and lail lamp? No brake light?

In most places, this means still not street legal.

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#11

Re: Motorbike Stator Coil

06/21/2011 1:13 PM

Most off road Motorcycles have an Enduro/Road equivilant which would have the relevant lighting coils.These can usually be obtained fairly cheaply from Bike Breakers /Wreckers and would fit directly or with very little work.The same with headlights/tail lights to conform to Road licensing laws if applicable.I wouldn't have thought an AC flywheel Mag setup capable of being reliable with extra loading as any moisture (rain) can play Havoc with generation.

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#12

Re: Motorbike Stator Coil

06/21/2011 5:46 PM

For about 50.00USD you can buy 2 high output/high quality bicycle lights. One white one in front for a head light, one red on in the rear for tail light and 250.00 left over for batteries.

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#13

Re: Motorbike Stator Coil

06/21/2011 7:38 PM

Here's my tuppence worth;

Measure what maximum voltage you get from this connection at what you consider to be maximum rpm. This is important as it determines all the other salient parameters.

Your not dealing with a lot of current, so you need to be "efficient" in your regulation. Use a switchmode regulator for your LED supply. It can be built on a postage stamp sized piece of veroboard.

In the diagram it appears that you have 3 phases, I would tap each of those phases with a diode ala alternator style. This would spread the load and give you a consistent dc voltage to work from, Using a diode like 1N5408 (3A 1000V) should be sufficient.

Even if you just use the identified wire rather than a 4 diode bridge, I'd use a 2 diode full wave rectification instead. Select a 1000uF electrolytic cap with suitable voltage headroom.

A LM2754HV switchmode regulator has a maximum input voltage of 60V dc and a nominal regulated output of 500mA at the the nominated voltage output or variable if that's the version you select. Plenty of others around, go to the National Semi website (www.national.com) and use the web bench.

The cool thing about switchmode regulators is that they will boost as well as buck the output voltage, and not use a whole lot of current doing it.

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#20
In reply to #13

Re: Motorbike Stator Coil

06/22/2011 1:46 PM

Tobuqrynbak:

Diode Trio, rectifier bridge, V-reg. keeping in mind feedback to the A/C circuit that fires the coil. usually a magnetic switch. Quite a bit of work actually and General increase of impedance in the coil circuit weakens the output. Overall the wattage required to power the lighting is nada compared to what it takes to run the circuit. If

Kind of like NASA, eh.∑

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#14

Re: Motorbike Stator Coil

06/21/2011 11:14 PM

I must agree that anyone with a title 'electrical engineer' would not need to ask such an elementary question. I also fear that IF the coil supplies both the ignition AND the proposed lights, the ignition may suffer, particularly at low revs. I had a Vespa scooter in the 50's but it had a separate coil for supplying the lights.

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#15
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Re: Motorbike Stator Coil

06/21/2011 11:25 PM

I think the ignition will suffer more at high RPM/high load than low.

I say this because(in my misspent youth) I had a Kawasaki KZ400 twin, and when I ran WFO at night the lights almost went out. When I backed off the throttle the lights got bright again. (I mis-spent my youth well into my 30's.)

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#16

Re: Motorbike Stator Coil

06/22/2011 5:30 AM

Why not just obtain a set of clip-on bicycle led lights which use 2 aaa batteries each, last quite some time and cost about 5 dollars for the set. Thought: there may also be some transient spike voltages in the stator coil since it's part of the high voltage spark coil circuit. Easiest, most economical solution would be self powered bike lights.

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#17
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Re: Motorbike Stator Coil

06/22/2011 11:10 AM

That was my thought too. If AAA batteries are not enough, get a small gel cell and strap it down somewhere and use the 12v. Seems a much easier and simpler solution. (But then I'm a simple person) You could probable fashion a bracket in less time than you could make the necessary circuit to use the stator coil.

(Just a side note on obtaining gel cell batteries. Here in the North East USA we have "yard sales" and quite often people sell off used kids toys (little cars that kids drive) with gel cell batteries in them or the batteries themselves. I've obtained several with 12v and 8 to 12 AH for less than $2 each.)

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#19
In reply to #17

Re: Motorbike Stator Coil

06/22/2011 1:31 PM

Tom

They sell complete kits for bikes, including: light, mount, (from screw to glue) and batteries. The headlights are quite powerful and removeable. I often ride my scooter here at night cause well, it's a Maui thing. To supplement the existing lighting wear one as a (human) headlight. Strangely enough the main problem is too much light which can really tick off oncoming drivers. I say this only in respect to the mention of money (value), so it has draw backs, as soon as I think of one I'll let you know. .... peace, sundog

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#21
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Re: Motorbike Stator Coil

06/22/2011 2:06 PM

Strangely enough the main problem is too much light which can really tick off oncoming drivers.
The problem is not too much light. It's the proliferation of sociopaths.
These sociopaths cannot resist the temptation to look at the car heading for them, and turn their head, aiming their headlight into the driver's eyes. Its not too much light, its incorrectly aimed light.
Did I read that you can now get fined $11,000 for shining a milliwatt-level laser at an airplane?

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#23
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Re: Motorbike Stator Coil

06/22/2011 9:31 PM

Correct

But I got away clean and all is well.

Sundog.

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#18

Re: Motorbike Stator Coil

06/22/2011 12:41 PM

The stator coil spits out an AC voltage obviously as it's mechanically powered from the motorbike crank...

Gives a whole new meaning to the term stator!

The electrical end of this is a no-brainer, (especially with the existing comments) so I won't add my tuppence.

But I would advise that you consider the utility of the light. Where you live, it may be possible to make a bike "street legal" with just a feeble headlight and taillight. But there may come a time when you actually want to use the headlight, and at that time you may find yourself riding without enough light output. Stay down around bicycle speeds and you'd be OK for picking out a path, but you would not be as visible to oncoming drivers as you would be with a real headlight. (1000 lumens is probably a reasonable minimum output for a single headlamp. HID lamps [as used on well-equipped cars] are more like 2500 -3000).

It is worth checking for a street-legal version of the same basic bike. These typically have a real lighting coil (separate from the ignition coil) a rectifier/regulator unit, a usable headlight, a small battery, etc. Often the flywheel is a little heavier, making the bike a little easier to ride at lower speeds.

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#22

Re: Motorbike Stator Coil

06/22/2011 2:10 PM

The job of an engineer is to simplify the task at hand, cheaper, more durable, but mostly simple. If we as engineers do our job correctly we provide a solution that makes the "why didn't I think of that" question, valid. If we do it real well we eventually engineer ourselves out of a job, but that was the initial idea. We seem to be in an age (again) and an agenda, to complicate things to a point that only the idea's parent can recognize the resulting child. Custody of that child not withstanding.

KISS (keep it simple stupid) was the solution to surviving the spectacular complexity of a US Navy submarine {and getting a ride home} It is also necessary sometimes to ask, which is what grounds us all, don't you think?

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