Go Back   EcoModder Forum > EcoModding > DIY / How-to
Register Now
 Register Now
 

Reply  Post New Thread
 
Submit Tools LinkBack Thread Tools
Old 12-12-2013, 05:36 PM   #1 (permalink)
EcoModding Apprentice
 
Jack-Lee's Avatar
 
Join Date: Jun 2013
Location: Germany
Posts: 126

Partygurke - '90 VW Polo 2F
TEAM VW AUDI Group

Rodi - '04 Smart Roadster Coupe
Thanks: 2
Thanked 63 Times in 41 Posts
DIY Alternator (permanent magnetic)

Hi,

my english still bad, but I try it.

After the battery of my car broke down, i buy a new one.
A LiFePO4 12V/8Ah battery
Safes 13kg! and incrasses the load efficienty from 60% to 90%.

As a result of this, i would reconstruct the alternator.
The old one weighs over 6kg and has an efficienty under 50%
The new one are an modified Brushless Motor with around 900Watts.(about 90% efficenty at generator)

An other coil winding and a "Stern Dreieck Schaltung" i would get a output voltage from 15-55V by an engine speed of 1000-5500U/min

The DIY charge controller should do this:
-controll the chargecurrent about 8Ampere but set the load current on it.
I explain: The controller load the battery with 8A. then i switch the lights on -> they need about 15A. So the controller current raise to 23A. I prevent an overcharge and i get enought Amperes for all consumers.
-overvoltprotection : Output Voltage: 14,5V
-overheatprotection: controller and generator
-undervoltprotection: prevent depth discharge
-autoswitch the "Stern/Dreieck" when the outputvoltage from the generator gains over 55V.
-display load/consumer current/power and batteryvoltage

The generator connect with the cam shaft over a cuppling (maedler.de/Article/60272400). Light and with a 100% efficenty.

I upload pics later

  Reply With Quote
The Following 2 Users Say Thank You to Jack-Lee For This Useful Post:
Ang84Indy (12-15-2013), Cobb (12-14-2013)
Alt Today
Popular topics

Other popular topics in this forum...

   
Old 12-14-2013, 02:25 PM   #2 (permalink)
Master EcoModder
 
Join Date: May 2012
Location: USA
Posts: 2,643
Thanks: 1,502
Thanked 276 Times in 226 Posts
Ive wondered about doing this. I see PM alternators for wind generators where a alternator was convereted to use magnets vs an electric magnet.
  Reply With Quote
Old 12-16-2013, 01:01 PM   #3 (permalink)
Corporate imperialist
 
oil pan 4's Avatar
 
Join Date: Jul 2011
Location: NewMexico (USA)
Posts: 10,546

Sub - '84 Chevy Diesel Suburban C10
SUV
90 day: 19.5 mpg (US)

camaro - '85 Chevy Camaro Z28

Riot - '03 Kia Rio POS
Team Hyundai
90 day: 30.21 mpg (US)

Bug - '01 VW Beetle GLSturbo
90 day: 26.43 mpg (US)

Sub2500 - '86 GMC Suburban C2500
90 day: 11.95 mpg (US)

Snow flake - '11 Nissan Leaf SL
SUV
90 day: 141.63 mpg (US)
Thanks: 253
Thanked 3,377 Times in 2,673 Posts
I use FeLiPO4 batteries in my diesel and replaced over 120lb worth of batteries and battery trays with about 20lb of lithium and assorted parts and the standard alternator has worked perfectly.
__________________
1984 chevy suburban, custom made 6.5L diesel turbocharged with a Garrett T76 and Holset HE351VE, 22:1 compression 13psi of intercooled boost.
1989 firebird mostly stock. Aside from the 6-speed manual trans, corvette gen 5 front brakes, 1LE drive shaft, 4th Gen disc brake fbody rear end.
2011 leaf SL, white, portable 240v CHAdeMO, trailer hitch, new batt as of 2014.
  Reply With Quote
Old 05-09-2015, 05:20 PM   #4 (permalink)
EcoModding Apprentice
 
Jack-Lee's Avatar
 
Join Date: Jun 2013
Location: Germany
Posts: 126

Partygurke - '90 VW Polo 2F
TEAM VW AUDI Group

Rodi - '04 Smart Roadster Coupe
Thanks: 2
Thanked 63 Times in 41 Posts
Hi,
the new alternator is not ready jet, but i work on it.
The electronic is much simplier as i think.
When the Battery (LiFePo4 12V/8Ah) is full and the Voltage raise over 14,4V, the alternator disconnect from the recifier and runs "free".
Only the "Stern-Dreieck-Schaltung" get it in.

On the Photo you could see the new alternator (in the middle), the old Beltdrive (left) and the cambelt gear-wheel.

The alternator jet get drive with a small toothed belt which runs on plastic gear wheels.
The complete Unit wight under 1kg.

Patrick

Attached Thumbnails
Click image for larger version

Name:	DSC_1021_002.jpeg
Views:	600
Size:	90.6 KB
ID:	17538  
  Reply With Quote
Old 06-13-2015, 03:21 PM   #5 (permalink)
EcoModding Apprentice
 
Jack-Lee's Avatar
 
Join Date: Jun 2013
Location: Germany
Posts: 126

Partygurke - '90 VW Polo 2F
TEAM VW AUDI Group

Rodi - '04 Smart Roadster Coupe
Thanks: 2
Thanked 63 Times in 41 Posts
Hi,
i buy a normal Alternator today.. My BL Alternator gets to expensive. I need a 50A Solar-Chargecontroller and a Variomatic -> over 400€ :/
The Alternator is now a Bosch EL 14 40/110A.
But this thing gets modified for a max. efficenty (Schottky-Diodes, low rpm,)
  Reply With Quote
Old 07-08-2015, 07:24 PM   #6 (permalink)
EcoModding Apprentice
 
Jack-Lee's Avatar
 
Join Date: Jun 2013
Location: Germany
Posts: 126

Partygurke - '90 VW Polo 2F
TEAM VW AUDI Group

Rodi - '04 Smart Roadster Coupe
Thanks: 2
Thanked 63 Times in 41 Posts
Hello,
today i messured 3 standard alternators and my DIY alternator.
Driven by my small lathe, i could test as far as 700W Input.

Im happy with my work and suprised that 20 years of technical development nothing change in effictiviness... ALternator 1: BJ:1991, Alternator 2: BJ: 1996, ALternator 3: BJ 2014

Here my results
Attached Thumbnails
Click image for larger version

Name:	Lima Kennlinien.jpg
Views:	70
Size:	111.6 KB
ID:	18260  

Last edited by Jack-Lee; 07-09-2015 at 09:50 AM..
  Reply With Quote
The Following User Says Thank You to Jack-Lee For This Useful Post:
iveyjh (07-08-2015)
Old 07-08-2015, 09:00 PM   #7 (permalink)
Master Novice
 
elhigh's Avatar
 
Join Date: Jan 2008
Location: SE USA - East Tennessee
Posts: 2,312

Josie - '87 Toyota Pickup
90 day: 40.02 mpg (US)

Felicia - '09 Toyota Prius Base
90 day: 52.92 mpg (US)
Thanks: 427
Thanked 614 Times in 449 Posts
Stern Dreieck Schaltung = Star-Delta switch for changing the alternator's voltage output - neat detail.
Verslustleistung = power dissipation (power required to drive the alternator)
Wirkungsgrad = efficiency
Ausgangleistung = power output

__________________




Lead or follow. Either is fine.

Last edited by elhigh; 07-08-2015 at 09:11 PM..
  Reply With Quote
The Following User Says Thank You to elhigh For This Useful Post:
Jack-Lee (07-09-2015)
Reply  Post New Thread


Thread Tools




Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2022, vBulletin Solutions Inc.
Content Relevant URLs by vBSEO 3.5.2
All content copyright EcoModder.com