generator

112 Articles

A Voltage Regulator Before Electronics

March 16, 2026 by 19 Comments

Did you ever wonder how the mechanical voltage regulator — that big black box wired up to the generator on a car from the ’60s or before — worked? [Jonelsonster] has some answers.

For most people in 2026 an old car perhaps means one from the 20th century, now that vehicles from the 1990s and 2000s  have become the beloved jalopies of sallow youths with a liking for older cars and a low budget. But even a 1990s vehicle is modern in terms of its technology, because a computer controls the show. It has electronic fuel injection (EFI), anti-lock braking system (ABS), closed loop emissions control, and the like.

Go back in time to the 1970s, and you’ll find minimal electronics in the average car. The ABS is gone, and the closest thing you might find to EFI is an electronic ignition where the points in the distributor have been replaced with a simple transistor. Perhaps an electronic voltage regulator on the alternator. Much earlier than that and everything was mechanical, be that the ignition, or that regulator.

The video below the break has a pair of units, it seems from 1940s tractors. They would have had a DC generator, a spinning coil with a commutator and brushes, in a magnetic field provided by another coil. These things weren’t particularly powerful by today’s standards and sometimes their charging could be a little lackluster, but they did work. We get to see how, as he lifts the lid off to reveal what look like a set of relays.

We’re shown the functions of each of the three coils with the aid of a lab power supply; we have a reverse current relay that disconnects the generator if the battery tries to power it, an over-current relay that disconnects the field coil if the current is too high, and an over-voltage relay that does the same for voltage. The regulating comes down to the magnetic characteristics, and while it’s crude, it does the job.

We remember European devices with two coils and no field terminal, but the principle is the same. There is never a dull moment when you own an all mechanical car.

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Off-Grid Electricity And Hot Water From Scrap Wood

March 14, 2026 by 41 Comments

Cooking with charcoal is a fairly common human activity, as much as others have come to prefer fuels like propane and propane accessories for their outdoor, summertime grilling. Although it’s made from wood, it has properties that make it much more useful for cooking — including burning at a higher temperature and with more consistent burn rates. It can also be used as a fuel for generating heat and electricity, but since it’s not typically found lying around in the forest it has to be produced, which [Greenhill Forge] has demonstrated his charcoal production system in one of his latest videos.

The process for creating charcoal is fairly simple. All that needs to happen is for wood to be heated beyond a certain temperature in the absence of oxygen. At this point it will off-gas the water stored in it as well as some of the volatile organic compounds, and what’s left behind is a flammable carbon residue. Those volatile organics are flammable as well, though, so [Greenhill Forge] uses them to heat the wood in a self-sustaining reaction. First, a metal retort is constructed from a metal ammo box, with a pipe extending from the side and then underneath the box. A few holes are drilled in this part, and the apparatus is mounted above a small fire on a metal stand. With the fire lit the wood begins heating, and as it heats these compounds exit the pipe and ignite, adding further fuel to the fire. Eventually the small fire will go out, allowing the retort to heat itself on the gasses released from the wood alone.

To generate the hot water, [Greenhill Forge] has taken an extra step and enclosed the retort in a double walled metal cylinder. Inside the cylinder is a copper tube packed in sand, which harvests the waste heat from the charcoal production for hot water. In his test runs, the water in a large drum was heated to the point that the tubing he used for the test began to melt, so it is certainly working better than he expected.

After the retort cools, [Greenhill Forge] uses the charcoal in another process that generates about a days’ worth of electricity and hot water. It’s part of a complete off-grid system that’s fairly carbon neutral, since trees are an abundant renewable resource compared to fossil fuels. Heating with wood directly is still common in many cold areas around the world, with the one major downside being the labor required to keep the stove running. But we’ve seen at least one project which solves this problem as well.

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Railway End Table Powered By Hand Crank

March 5, 2026 by 10 Comments

Most end tables that you might find in a home are relatively static objects. However, [Peter Waldraff] of Tiny World Studios likes to build furniture that’s a little more interesting. Thus came about this beautiful piece with a real working railway built right in.

The end table was built from scratch, with [Peter] going through all the woodworking steps required to assemble the piece. The three-legged wooden table is topped with a tiny N-scale model railway layout, and you get to see it put together including the rocks, the grass, and a beautiful epoxy river complete with a bridge. The railway runs a Kato Pocket Line trolley, but the really neat thing is how it’s powered.

[Peter] shows us how a small gearmotor generator was paired with a bridge rectifier and a buck converter to fill up a super capacitor that runs the train and lights up the tree on the table. Just 25 seconds of cranking will run the train anywhere from 4 to 10 minutes depending on if the tree is lit as well. To top it all off, there’s even a perfect coaster spot for [Peter]’s beverage of choice.

It’s a beautiful kinetic sculpture and a really fun way to build a small model railway that fits perfectly in the home. We’ve featured some other great model railway builds before, too.

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A Working Intercom From Antique Telephones

February 9, 2026 by 13 Comments

Although it can be hard to imagine in today’s semiconductor-powered, digital world, there was electrical technology around before the widespread adoption of the transistor in the latter half of the 1900s that could do more than provide lighting. People figured out clever ways to send information around analog systems, whether that was a telegraph or a telephone. These systems are almost completely obsolete these days thanks to digital technology, leaving a large number of rotary phones and other communications systems relegated to the dustbin of history. [Attoparsec] brought a few of these old machines back to life anyway, setting up a local intercom system with technology faithful to this pre-digital era.

These phones date well before the rotary phone that some of us may be familiar with, to a time where landline phones had batteries installed in them to provide current to the analog voice circuit. A transformer isolated the DC out of the line and amplified the voice signal. A generator was included in parallel which, when operated by hand, could ring the other phones on the line. The challenge to this build was keeping everything period-appropriate, with a few compromises made for the batteries which are D-cell batteries with a recreation case. [Attoparsec] even found cloth wiring meant for guitars to keep the insides looking like they’re still 100 years old. Beyond that, a few plastic parts needed to be fabricated to make sure the circuit was working properly, but for a relatively simple machine the repairs were relatively straightforward.

The other key to getting an intercom set up in a house is exterior to the phones themselves. There needs to be some sort of wiring connecting the phones, and [Attoparsec] had a number of existing phone wiring options already available in his house. He only needed to run a few extra wires to get the phones located in his preferred spots. After everything is hooked up, the phones work just as they would have when they were new, although their actual utility is limited by the availability of things like smartphones. But, if you have enough of these antiques, you can always build your own analog phone network from the ground up to support them all.

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Hackaday Links: December 7, 2025

December 7, 2025 by 17 Comments

We stumbled upon a story this week that really raised our eyebrows and made us wonder if we were missing something. The gist of the story is that U.S. Secretary of Energy Chris Wright, who has degrees in both electrical and mechanical engineering, has floated the idea of using the nation’s fleet of emergency backup generators to reduce the need to build the dozens of new power plants needed to fuel the AI data center building binge. The full story looks to be a Bloomberg exclusive and thus behind a paywall — hey, you don’t get to be a centibillionaire by giving stuff away, you know — so we might be missing some vital details, but this sounds pretty stupid to us.

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Levitating Lego Generator Runs On Air

March 31, 2025 by 4 Comments

[Jamie] decided to build a generator, and Lego is his medium of choice. Thus was created a fancy levitating generator that turns a stream of air into electricity. 

The basic concept is simple enough for a generator—magnets moving past coils to generate electricity. Of course, Lego doesn’t offer high-strength magnetic components or copper coils, so this generator is a hybrid build which includes a lot of [Jamie’s] non-Lego parts. Ultimately though, this is fun because of the weird way it’s built. Lego Technic parts make a very crude turbine, but it does the job. The levitation is a particularly nice touch—the build uses magnets to hover the rotor in mid-air to minimize friction to the point where it can free wheel for minutes once run up to speed. The source of power for this contraption is interesting, too. [Jamie] didn’t just go with an air compressor or a simple homebrew soda bottle tank. Instead, he decided to use a couple of gas duster cans to do the job. The demos are pretty fun, with [Jamie] using lots of LEDs and a radio to demonstrate the output.  The one thing we’d like to see more of is proper current/voltage instrumentation—and some measurement of the RPM of this thing!

While few of us will be rushing out to build Lego generators, the video nonetheless has educational value from a mechanical engineering standpoint. Fluids and gases really do make wonderful bearings, as we’ve discussed before. Video after the break.

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Bosch Starter Motor Freed From Mercedes Prison

January 24, 2025 by 79 Comments

Vehicle alternators are interesting beasts. Produced on a massive scale, these electric machines are available for a minimum of cost and contain all kinds of great parts: some power electronics and a belt-driven generator are generally standard fare. This generator can also be used as a motor with only minor changes to the machine as a whole, so thanks to economies of scale it’s possible to get readily-available, powerful, compact, and cheap motors for all kinds of projects using alternators as a starting point. [LeoDJ] noticed that this starter motor in a modern Mercedes had some interesting benefits beyond all of these perks, but it took a bit more work to get up and running than a typical alternator would have.

The motor, built by Bosch, can be found in the Mercedes E200 EQ Boost. This is a hybrid car, but different than something like a Prius in that it doesn’t have an electric motor capable of powering the car on its own. Instead it uses a combination starter motor/alternator/generator to provide extra power to the engine during acceleration, increasing efficiency and performance. It can also charge the small battery bank when the car slows down. Vehicles that use this system need much beefier alternators than a standard car, but liberating it from the car means that it has much more power available than a typical alternator would.

There were a number of issues to solve, though. Being that the motor/alternator has to do all of this extra work (and that it came out of a car whose brand is known for being tedious to work on in the first place) it is much more complicated than an off-the-shelf alternator. [LeoDJ] has been able to get his to spin by communicating with it over the CAN bus, but there’s still some work to be done before it goes into something like an impressively fast electric bicycle.

Thanks to [RoganDawes] for the tip!