How to Assemble a HHO Generator and Why It Works

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How an HHO generator works and helps you save gas

An HHO or Brown gas generator is an interesting and often misunderstood technology.
The Brown gas generator uses electrolysis to split water (H2O) into it´s base molecules, 2 hydrogen and 1 oxygen molecule.
This is why it is often referred to as an HHO gas generator.The HHO in itself is not an alternative to gasoline but a additive
to boost the efficiency of the engine. Gasoline engines are unfortunately not burning gasoline to its full potential. See http://en.wikipedia.org/wiki/Engine_efficiency
The average gasoline engine in a car is about 18% to 20% efficient. That leaves a lot of room for improvement and Brown gas is one good way of improving the efficiency. The reason for this is simple, the hydrogen is highly flammable much more so than gasoline so when your engine ignites the hydrogen the explosion ignites the gasoline with much better results (cleaner, less waste and fewer emissions) than it would otherwise have done.

Some basics the burn speed of hydrogen is 0.098 to 0.197 ft/min (3 to 6 cm/min) compared
gasoline´s 0.00656 to 0.0295 ft/min (0.2 to 0.9 cm/min).

The hydrogen explosion is so fast that it fills the combustion cylinder at least 3 times faster then the gasoline explosion and subsequent ignites the gasoline from all directions  (it is like putting flue on a fire), instead of just a spark in one end of the combustion cylinder, and we would like to do that because the gasoline only has a short time in the combustion cylinder and if its not fully burnt in that short amount of time then it just goes out the exhaust and is lost.It is also preferable to ignite all of the gasoline when it is under maximum compression in combustion cylinder to get the maximum amount of energy out of it (this is a small time window),whonce the piston starts going down the energy transfer from the explosion to the engine becomes less efficient.

The hydrogen´s higher burn temperature and explosive force is such that it cleans the soot that collects in the engine (it is like having the engine consistent maintains) and with a cleaner engine you get better mileage and fewer oil changes .


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Step 1: Tools and Main Components

Tools:

Screwdriver
Glue gun
Drill and bits
Metal saw
Soldering iron
wire crimp
wire cutters

Components:

HHO Generator
Pulse width modulator (PWM)
Electronic Fuel Injection Enhancer (EFIE)
Electric wires
Hose
Air connector
On/Off switch
Straps
Cable connectors
One way air valve
Piece of sheet metal
Peace of rubber
Glue

Step 2: The Brown Generator

I modified the Brown generator I bought on ebay by adding connections to the places and replacing the spacers with smaller ones to increase the surface area.
You will have to buy bottled water because tap water can have  metal in it that will rust the plates.
You will also have to ad an electrolyte to the water  to speed up the electrolysis.
The highest production of  hydrogen occurs with the plate polarity alternate as in +-+-+.( It also consumes the most amount of electricity)

Step 3: Pulse Width Modulator


Is an important tool to control the electrolysis. A simple generator can be built without PWM but that is like having an engine with only the possibility of full throttle or no throttle at all. The pulse width modulator is necessary for a controlled electrolysis. The specific frequency and power for the most efficient electrolysis wares form generator to generator.
You will have to fine tune the PWM your self but that is simple. You just fine tune the frequency first, by tuning the frequency up until the bubbles from the electrolysis plates start decreasing after you hit maximum bubbles and then go back to the best setting (producing the most
amount of bubbles) and then do the same for the power setting. It is best to get a powerful PWM at least 35 Amps preferably more.

I use a 50 Amp PWM and a LCD Display from canakit. http://www.canakit.com/50a-dc-pwm-motor-speed-controller.html

Step 4: EFIE

EFIE (Electronic Fuel Injection Enhancer)

The EFIE is intercepting signals from the oxygen sensor to the computer and fools the computer by giving it false exhaust readings from the Oxygen sensor.This is necessary because the computer is set up for a regular burn of fuel and compensates for the more efficient and cleaner burn by dumping more gasoline into the engine (until it gets the reading it expects) which ruins your fuel savings.
Gasoline burns better (cleaner less waste) with HHO gas because the increase burn temperature .

You can buy a EFIE on the internet or if you have the skills you can build one.

Step 5: Installation

I made a hole for the wires from the PWM to the Brown generator along side the existing electric cables,
the I put a peace of metal (with rubber on one side) around the Brown generator and screwed it to the frame of the car.
I drilled a hole in the air intake behind the air filter and inserted the air connector. I then put one way air valve on the hose
and connected the Brown generator to the engine.

Then I lengthen the cables of the PWM, thunk the variable resistors out and attached them til long wires, I also mad an manual on-off
switch  extension. I then used the glue gun to glue the PWM  to the top of the small glove box under my steering while,connected the wires slid the glove box into place  and then glued the variable resistors and the LCD Display in the small hatch where the fuses are.
It is all easily accessible bot not visible.
 


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    167 Discussions

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    level.99.novice

    16 days ago on Step 2

    ANYONE ATTEMPTING TO FOLLOW, PLEASE READ :

    PELIGRO: POR FAVOR LEA
    :

    lengthy warning
    Stainless Steel for your electrodes? If you are using that, I urge you to go and look up on the web on the dangers of using those as electrodes! Stainless Steel leaches out Hexavalent Chromium! - Toxic, a known Carcinogen (very carcinogenic, It seems - and is severely regulated) and illegal to dump out! This is a legitimate concern and I urge you to Do Good Research on it Yourself, just like You Should with Anything Else, Please! ... According to sources, even if it isn't visible, Chromium is leaching out.

    The Specific Stainless Steel Grade, Number of Plates, Voltage administered to the Plates, and the Electrolyte, all Affect the Leaching of Hexavalent Chromium. So I Urge Looking into How These Parts Interact with each other

    Make sure your materials or alternatives, Electrodes and Electrolyte (like the type of water and electrolyte solution used (RO water, KOH, other made Electrolyte Solutions etc) , is Safe for your System - Confirm your Information and Everything with Resources etc. According to one person, Stainless Steel is just better avoided to prevent Any chance of Hexavalent Chromium leaching..

    PLEASE : Wear Proper Safety Equipment (masks, googles, gloves etc.) Don't Drop stuff. Take Working Precautions, Dispose of the Waste Safely and Responsibly (You Don't want the Dust and Saturated Water to spread back into Your or, Especially, Others' Breathing Environment, the Air and Water supply, right?). Look Up and Research on how to Safely Handle all these things and activities as well! Please be Careful guys
    (This applies to Any/Every Situation too)

    https://www.osha.gov/OshDoc/data_General_Facts/hex... (general)

    It shouldn't be as big of a problem (PROBABLY- Please Look It Up) on a small scale, as the Stainless Steel's Hexavalent Chromium leaches out more slowly as compared to large scales - but handling will definitely saturate the water with it, and it'll be a problem then. Even very small quantities are dangerous according to EPA and related gov't groups' fact sheets (but you also have to consider the context of frequency of exposure.) Though here's hoping that the amount leached off in small scale systems like this overtime is so insignificant, and the spread of it back into the air dilutes the concentration of the dust so much, that it will have no impact on health and not be a problem

    ALSO : I don't mean to worry you or anybody, but inform about the risks. I'm just a person who is worried. I may even be mistaken - so please look it up for yourselves,

    if you've become concerned about it, it should be fine as long as you weren't inhaling it and drinking it, exposure matters too, which should be less on hobbyists as compared to occupations which deal with this stuff, which the statistics are based on (I'm basing this on my personal, cursory skimming on govt papers/articles/statistics on the web of chronic exposure of it - over long periods of time and warnings/cautions on forums and comments. The people [I've, personally , read about] affected are those from Inhaling the chromium during Welding and similar occupations/other not Electrolysis [ I do only have limited knowledge, just correlation. But, I have already read others AGREE that Electrolysis does leach out Hexavalent Chromium ] But Do Good Research on it Yourself, just like You Should with Anything Else, Please! ). If it's been some time, your body's immune system does have an ability to fight against cancer.. I, personally , haven't gone looking enough for anything explicit about anyone getting cancer in this particular way yet, but it does not mean it does not occur!, just that this specific case hasn't circulated yet or I haven't found it yet! I'm not related to Chicken Little (though I do hope I'm just being paranoid).

    This just a warning on the internet that hopes to prevent any accident. Like I said, I may be wrong, and this is sort of long... - But Remember periodic Medical check-ups and Please Stay Safe People. :) i love you <3

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    DarkStarPDX

    8 years ago on Introduction

    I'm pretty sure the additional electricity your alternator has to provide to generate the hydrogen outweighs the additional efficiency provided (a.k.a. perpetual motion). Throw some large solar panels on the top of your car/truck to power the HHO generator exclusively and then you might have something.

    18 replies
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    lucekDarkStarPDX

    Reply 8 years ago on Introduction

    Yeah he's got a rather poorly designed pseudo electric car. Forget the fact that even with a pretty good energy source thees devices can't produce that much gas/minute. producing the same amount of force from thees it take 3 times the mass of water then gasoline. You rarely see one of thees devices with more than a few gallons of water. And again is you have the perfect device at the theoretical best efficiency 94% (best devices ever made are in the range of 70%, I've not tested this device but a device in a lab under perfect conditions are working at 70% this ain't even close.)

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    JayY2lucek

    Reply 1 year ago

    It appears to me as if you are thinking this is a replacement system for normal fuels: It isn't. It's designed as a supplemental enhancer. That's why such small containers are used in the system, and even those last quite some time (length of use pending on voltage amount applied). Hydrogen only cars require compressed gas (which is more dangerous) and a use specific intake system, while the HHO generator system adds an enhancer and not a primary fuel. On older carburated vehicles no modifications need be done to the intake system other than adding a hose into the air intake, while computer controlled systems (EFI) will need an O2 sensor tweak, which can be done to already existing engine management systems with a programming module, and with a small enough input of HHO even that isn't required.

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    JayC97JayY2

    Reply 1 year ago

    The "O2 Tweak" is why it works. You are making a rich air fuel mixture that produces more NOX and damages the engine over time while squeaking out a few percent more energy. This is why all tests of thees devices fail to tell if they are on or off.

    The physics says what you are saying is wrong.

    The test on thees devices do as well.

    Really it's only the people who invested time and money into them that say they work and even with that the physics defying mechanisms are diferent for different people. It's not replicable. It's pseudoscience.

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    JayY2JayC97

    Reply 1 year ago

    Actually, burning HHO produces water, NOT NOX. The tweak is needed ONLY because there is more oxygen introduced into the system, which comes out the exhaust as water vapor (STILL H2O), and the O2 sensor reads as a lean state. On older carbureted systems you don't even have to do any of that. You are NOT damaging your engine with this system UNLESS you make such a drastic change to the oxygen sensor readings that it says you are using a gallon of petrol/second so cuts the petrol injected to nil, and I don't think ANY O2 sensor can be adjusted that much.

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    JayC97JayY2

    Reply 1 year ago

    That's what people claim but it actually decreases the air fuel ratio meaning more nitrogen is oxidized after the hydrocarbons have been exhausted. Also messing with the air fuel ration causes knocking and will damage the pistons and cylinder wall over time.

    To anyone who isn't JayY2 Before investing the time effort and money into making/buying one of thees devices. I wish people like JayY2 would test their own claims but I do not hold out hope. I do not think him a scammer or deluded or stupid just falling into the trap of motivated reasoning we all can. And that is a bigger lesson we should all take away. We are all fallible. Test what you hold most dear because that is where you are most likely never to look.

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    DanielW357JayC97

    Reply 6 weeks ago

    OK so port directly into the vacum stator line instead of the air intake so you dont have to buy something else to fool the MAF and force the computer to adjust gas levels to compensate for anything. run the tube to the vacum line which is anywhere past the MAF

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    DanielW357JayY2

    Reply 6 weeks ago

    ok so use 3 jars if you need to make three times the hydrate

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    JayY2lucek

    Reply 1 year ago

    These are fuel SUPPLEMENTAL systems, NOT fuel replacement systems. You can run a vehicle off straight hydrogen, but that is not what these on-demand systems are for. They are merely for causing the fuel you pump into the tank to burn more efficiently. They are NOT perpetual and NOT classified as perpetual. I don't know where that came from: Probably from Big Oil companies trying to kill it.

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    JayC97JayY2

    Reply 1 year ago

    No it doesn't. Every single time these are tested by people who aren't invested in HHO they don't work.

    Again it doesn't matter if it's supplement or replacement or catalyst (which it isn't even close) conservation of energy comes to play. Any energy generated by the burning of the brown gas can only I repeat can only produce at most the energy used to split the water. That's with 100% efficiency in every part of the system. Best case scenario in make believe world this adds nothing to the system but extra weight. Even that is crazy however as getting 10% efficiency total is a pipe dream.

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    JayY2JayC97

    Reply 1 year ago

    There are MANY people who make these systems JUST for being interested in them, and other than for the learning the aren't "invested" in them, which denotes making a profit off it. These people, myself included, have seen and proven it to work. Heck, you can even make fuel for a car from burning wood (look it up). I personally make nothing from any of this, other than hopefully to reduce the carbon footprint of us humans. I'm not a "treehugger", I am a realist that seeks for ways to save money any way I can, and buying less petrol IS saving money. Oh, and oxygen IS a catalyst (the O in H2O).....

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    JayC97JayY2

    Reply 1 year ago

    No I never said anything about profit. I said invested. I.E. The time money and or effort they invested in making thees devices motivates people to see them working. That's why people attempt to prove that they work not to test the devices. Again simply doing things like disconnecting the brown gas flow and noting there is no difference in engine performance with the modifacation in place.

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    A SchmuckJayC97

    Reply 1 year ago

    It help the eff of the engine it’s used on that’s all

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    lapsiklucek

    Reply 4 years ago

    For every gallon of water you can get 4707 litres of H2, thats at atmospheric pressure and freezing point. So, it would seem on the face of it that H2 production by electrolysis is worthwhile. I agree the main problem is producing enough to properly suppliment your current fuel, but this talk of inefficiencies and costing more to produce than it delivers is hogwash. The weight of an H2 generator is under 10kg fully loaded. The H2 generated will improve combustion, reduce emmissions and should save money long term. Thats 3 positive benefits. "There are none so blind as those who will not see"

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    PierreM33lapsik

    Reply 3 years ago

    On an enegy level, there is no difference, no improvement.. but on the COST side, yes there could be a lot on money saved.. water cost a lot less then gasoline (unless you drink Perrier) but tap water in here is cheap, real cheap and if it can help some fuel.. that is where someone will save.. But not on the energy ratio created.

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    lucekPierreM33

    Reply 3 years ago

    If the electrolysis of the water and combustion of the brown gas were 100% efficient (which physics tells us they aren't) there would be no net increase in energy produced by the engine. So no burning brown gas produced by electrolysis is more costly. IE it is infinitely more costly. You are wasting money to do nothing. But as said above that is if the system is 100% efficient, it only get's worse when we start talking about 30% efficient engines and 40% efficient alternators and a electrolysis device with no known measure.

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    JayY2lucek

    Reply 1 year ago

    You are presupposing that the system is being used to supplement energy output, and that is where you are erring. It replaces some of the petrol being burned, and the oxygen present helps any fuel burn more efficiently, therefor, these systems (which have an efficiency of around only 30 to 40% on average) do increase mileage by replacing some of the petrol being used. It is NOT done to increase energy output, but to replace a portion of the petrol and make what is used more oxygenated therefor being more efficient. And yes, you can increase performance by introducing pure oxygen into the intake system, but that is much more costly, and more dangerous.

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    luceklapsik

    Reply 4 years ago on Introduction

    Flat out no it doesn't. Messing with the O2 sensor changes compression increases pollution and damages the vehicle. Adding the trickle of brown gas does just about nothing either way. Don't trust me. Look up tests where the system is turned on and off without messing with the O2 censor. Hell do it yourself. Efficiency increases when the brown gas generator is off.

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    lapsiklucek

    Reply 4 years ago

    3 ways to easily bypass the O2 sensors, remove them, remove the cat(s or fool the ecu into thinking your not running too lean. If you take off the cat(s) you gain a much free'r flowing exhaust. If you then are able to produce sufficient hydrogen to effect efficient combustion then you will have a cleaner burning more efficient SI/CI engine. Just bypassing or removing the O2 sensors wont have a detrimental effect on the engine, it will have a detrimental effect on the cat(s), so best to remove them.