Controller mods or build for E-assist altermotor

[freebeard]

Sorry if I spoiled the reveal.

The battery is 1.3 Kwh I believe, so, of not much use except for an e-bicycle, maybe. I would like to have parts in hand before guessing what they do.

The capacity sounds about right for the KERS functionality, but I was surprised by the apparent size in the video. I guess it includes the controller and DC-DC inverter.

I noticed that there is one interlock to turn it on, but an interlock on the interlock to prevent it turning off.

[HaroldinCR]

Freebeard: All good on your reveal. I was just holding off.

I think ALL the electronics are inside the battery case. The cable from that case runs directly to the alternator. Just need to supply 12v to turn on the system, I believe.

I'm hoping the low battery feature is what changes the motor phase back to charge phase. According to the Buick car video, when the engine was running, no charge was happening to the 2/3rd charged battery. When the guy did something different, the battery started charging toward full.

All that interlock stuff would not be necessary for us. Just a key switch and pre-charge solenoid/relay.

12 more days until I get to tear into stuff. Once I get there, I can start hounding salvage yards for a bad battery/electronics unit.

[HaroldinCR]

Found some photos of GM controller/battery connections. Copied from iATN.net and martin from British Colombia ? They were freely able to be copied, so, if anyone has a problem with this, contact me.

May not be any help unless we get BAS controllers.

[freebeard]

I quote pretty freely, because that's what Internet is all about. Better to ask forgiveness than permission.

I do annotate with a link [in italic] if it's not from my Ecomodder albums.

[HaroldinCR]

Just got word that altermotor is at my Son's house. He says rough measure is 8" dia X 9" long X 2" shaft length. Actual measure can be sent here if it is really needed, before I get up there in 9 days.

[freebeard]

There is no hurry based on my wallet.

I'm most curious about the mounting points and whether that junction box unbolts.

[HaroldinCR]

Hey guys
Got into Florida last night. Altermotor is sitting in the garage along with the Honda IMA controller/inverter and Ford EV controllers/inverters.

Hope to get things out in the open today and get this party started. Hope Paul has a few minutes to get on here and help with a few questions I have. Thingstodo, E-clipse, and others I hope will chime in.

Need Engineering assistance badly.

Actual measurements of the altermotor are 8" long, possible a 1/2" shorter if the water cooling tubes need to be modded a bit, and, yes, the case part of the power connections can be removed, leaving the case open at that location. It measures 7 1/2" in diameter and with a 1 1/2" long shaft.

The resolver takes a 10 conductor cable, which the yard effectively cut, so, testing which wire is which will need to be sorted. Power cable is also cut, but the connector and rubber cover are intact.

More later as I dig for the controllers.

[freebeard]

That sounds encouraging. When I measured one under the hood, it appeared to be 8" including the pulley. Is that right?

My hope would be that the junction box could just lay on the top of the VW engine case, with the fan shroud notched to fit over it.

[HaroldinCR]

No, including the pulley is 9 1/2". It IS possible to shave off a little and get closer to the 8", but, as I measured this one, 8" would be without the shaft/pulley.

Maybe we could better fit this If I could see a figure/photo, etc. of what you are thinking about doing.

[freebeard]

I am willing to go the other way, given a 3-view drawing of the component part; but Okay:


vwtype3.org / Owner's Manual: Mechanical


Barbuza - Automotive Photo Editor

Either cooling fan setup fits the [universal] case. The distance from the upright fan shroud rear face to the generator pulley face is 8" (by inspection). Replacing the stock generator seems problematic since the resolver is where the fan would want to be. OTOH an air-conditioning compressor can be fitted under the stock engine compartment lid and they are similar in size.

The Beetle engine compartment is confining, but [those in] Buses, Karmann Ghias and Bajas are not.