Revolution

Revolution is a DIY approach to gravity light, a product which produces light by raising a weight and letting it fall to generate electricity. My version revolves around a DC generator built from a modified washing machine motor and some old bicycle gearing.

The project is meant to bring awareness of how we can reuse 'waste' and how we take electricity for granted.

The aim was to produce something useful from old components which would otherwise be thrown away. By combining them with some 3D printed parts, a wooden base, and some electronic components I’ve designed an system which can be made by anyone anywhere.

I have a strong interest in renewable energy, especially kinetic as there is so much to experiment with and the mechanisms fascinate me.

Step 1: Tools and Supplies

The above table contains all the supplies required to build a

DIY gravity light.

Recommended Tools:

3D Printer

Laser Cutter/CNC Machine

Spanner

Hacksaw/Angle Grinder

Metal file

Screwdriver

Chain tool

Step 2: Laser/CNC Files

Step 3: 3D Print Files

Step 4: DC Generator Part 1

The first step is to build your DC generator, I used an old washing machine motor for this project, but I’ve also had success with car alternators in the past. Any large motor can be used so use whatever you have available.

Begin by taking apart the motor, in this example I had to undo 4 large bolts.

Next remove the shaft and put the rest to one side.

Now remove the existing magnet, in this example it’s the large darker metal cylinder, I found an angle grinder with cutting disc to be most effective, but a hacksaw will also work.

You should now have a shaft with just the bearings remaining.

Now it is time to take 4x Magnet holder prints and align them on the shaft where the old magnet was. Once they’re in place secure the magnets in the grooves with some super glue. This can be seen in the video above.

Step 5: DC Generator Part 2

Now it’s time to reassemble the motor with the modified

shaft.

Use the same method as when you took it apart and pay attention to any small washers or spacers to ensure everything fits together properly.

The video above shows the reassembly process of my motor.

Once assembled attach the front and rear mounts you 3D printed earlier.

Step 6: Cassettes

Next move onto the cassette assembly, as I was reusing old

ones they were covered in oil and dirt, so I gave them a clean before I started.

Make sure you have your bearings, cassette mount bearing print and a section of m10 threaded bar roughly 90mm long and accompanying nuts and washers.

Start by pushing the printed part into the cassette pay attention to the splines as they are not symmetrical, there is one small one, so it won’t fit unless lined up correctly.

It is a very tight fit so some force may be required.

Next press a bearing into each end of the print.

Now insert the bolt and tighten a nut either side of the cassette, we’ll space it properly later.

For the remaining cassette push the cassette mount motor
print instead, this one doesn’t require bearings.

Step 7: Base

Now it’s time to construct the base and start putting
components together, the above image has several steps to follow with detailed images about the construction.

The video above also shows me putting my one together which you can follow along if you’d rather.

Step 8: Chain Lengths

As with the cassettes I reused old bike chains, so I washed and

degreased them before use.

Top tip, many bike repair shops have old chains laying around which they’ll give you for free as the are no longer fit for use on bikes but are still perfect for this project as we don’t have to worry about changing gears.

Start off by placing the chain around 2 cassettes and mark the length required, this will vary depending on the gear sizes on your cassette.

Now get your chain tool and use it to split the chain by turning the handle and pushing the pin, don’t completely remove the pin as this makes re-joining the chain more difficult.

Then re-join the chain to make a loop the size you need, repeat this for all 3 chain loops before attaching them to the cassettes on the base.

Step 9: Electronics

The electronics in this project are quite simple and due to

the low amperage, it is quite safe.

I started by identifying which cables on the motor were my positive and negative, I did this by eye and found the two solid red cables going to the back of the motor, I also confirmed this using a mustimeter and spinning the motor.

Mine came with spade bits already attached by if yours don’t now would be a good time to add some form of connection.

There is a whole cut out in the clear top panel for an LED, I built my own light using 5 large Diodes and a 3D printed enclose but for simplicity I recommend you by a cheap LED bulb with a low wattage requirement, ensure it fits in the hole or design a fixing for it yourself.

Now run the cabling from the motor up to the bulb, I twisted my wires together then secured them with heat shrink tubing however soldering them together would provide a more permanent joint.

I recommend fixing the wires in place, I used a staple gun for this, so that they can’t move around and get caught in the gear mechanism.