Picked up half a megawatt worth of Caterpillar power, think I'll make a PTO generator

[strantor]

How about making a chain "step up box"?
45T #60 sprocket on the input shaft (ie: X1-1/2B 1-1/2" Bore Hub | Weld-On Sprocket Hubs | Sprockets | Power Transmission | www.surpluscenter.com and X1-1/2B 1-1/2" Bore Hub | Weld-On Sprocket Hubs | Sprockets | Power Transmission | www.surpluscenter.com )
15T #60 sprocket on the output shaft (ie: 15T 1-1/2 Bore 6P Sprocket | Finished Bore Sprockets | Sprockets | Power Transmission | www.surpluscenter.com )
A box of 60H chain (ie: #6-1 H 1' Box Of #6 Heavy Duty Roller Chain | Roller Chain | Roller Chain & Links | Power Transmission | www.surpluscenter.com )
Mount them in a box that you size so that one side matches the SAE #2 bell on the generator head and fill with enough oil that the chain runs through it and slings it around and off you go.

Aaron Z

The thought crossed my mind but I did not seriously consider chain drive because chains are noisy and I thought they are not very efficient or reliable. Your post inspired me to dig deeper and I realize I was wrong. This is probably the best solution on the table currently. I've priced a handful of parts from surpluscenter (love that site, BTW) and I think i can make it work for pretty cheap. Thanks for your input!

 

[aczlan]

Glad I could help. Keep us posted on how you end up making it work.

Aaron Z

 

[MossRoad]

The thought crossed my mind but I did not seriously consider chain drive because chains are noisy and I thought they are not very efficient or reliable. Your post inspired me to dig deeper and I realize I was wrong. This is probably the best solution on the table currently. I've priced a handful of parts from surpluscenter (love that site, BTW) and I think i can make it work for pretty cheap. Thanks for your input!

Chains are very efficient and very reliable. But as mentioned, they must be lubricated, whereas a shaft doesn't.

 

[aczlan]

Chains are very efficient and very reliable. But as mentioned, they must be lubricated, whereas a shaft doesn't.

It's hard to increase speed with a shaft alone, generally speaking, some kind of (lubricated) gears are required

Aaron Z

 

[radios1]

These are single bearing units as well. I'll have to come up with my own solution for the 2nd bearing. Caterpillar doesn't make any two-bearing solution for it, not even an expensive one. The clutch bellhousings recommended earlier seem like they could help, but the flanges are inverted as they're meant to bolt to an engine, not a generator. And they're prohibitively expensive. I think I might repurpose the bolt-on section of housing which covers the fan, from the 2nd head, bolt it to first head, which will leave the shaft end recessed inside. From there I can fabricate a piece of plate with a hole and the center and bearing bolted in the center, and machine a stub shaft adapter which bolts where the existing flex plate is, and extends through the plate & bearing.

there are machinists on the internet that have been making such adapters for a reasonable price..

 

[MossRoad]

It's hard to increase speed with a shaft alone, generally speaking, some kind of (lubricated) gears are required

Aaron Z

Yeah! Gotta get some kinda special metal for that shaft! :laughing:

 

[aczlan]

Yeah! Gotta get some kinda special metal for that shaft! :laughing:

I suppose that if you got it to spring by shock loading it, it could spring forward and be a little faster, but not by much.

Aaron Z

 

[MossRoad]

There's all kinda science fiction that could resolve this issue nicely.... :laughing:

 

[chriswheeler]

I think the easiest way to get this thing up and running is the way cat intended. See if the engine end of this is available surplus for a good price as well. I think cobbling a rig together would work for sure at some point, but how much effort and money will be into it at that point. More of a sure thing with support built in rebuilding the engine end than putting something together that might work.
Chris

 

[strantor]

there are machinists on the internet that have been making such adapters for a reasonable price..

I may be in the market for that kind of service, I don't know. I'm a hobby machinist and I have a lathe big enough to turn a SAE1 adapter plate, but the lathe is a restoration project, currently in pieces. I also have a CNC mill that might be able to do the job, but it's also not quite ready. I recently completed the restoration and it's not yet tested. Also not sure if the table has enough travel to cut the whole plate without using a 4th axis rotary table. I have gone down several avenues of thought with regards to how I will DIY the adapter plate, and none of them are "quick & easy." But drawing up what I want in solidworks and sending it off to someone else surely would be. I would need an idea of cost before I could seriously consider it. If you or someone you know has the capability, please PM me with details. Thanks.