Paul & Sabrina's cheap DIY 144v motor controller

[MPaulHolmes]

The harbor freight generator puts out single phase power. I'm not sure what sort of motor it has inside there. If it was a 3 phase motor, you could definitely use it. I'm going to post all the stuff and you can definitely use it for a lower voltage and lower current application. It doesn't care about the voltage level used, or the current level.

[okie00]

Originally Posted by Alcibiades Ramos

Hey everybody, I have this crazy idea that maybe we can turn this generator into an AC motor:

http://manuals.harborfreight.com/man...5999/45416.pdf

Can someone give me some insight on what to expect if that were possible?

I am working on a budget so I'm trying to beat the system until they realize and jack up the prices he he!

And Paul if you don't mind I would like to help in this AC project. I would like to order a couple of AC boards and the list of items required to put together a couple of AC controllers.

One is going to go into my old Ford Aerostar and the other on my CBR1100XX which I am turning it into electric after seeing MotoCzysz win in Australia.
Peace.

Converting a Aerostar hows it going ?
I'm working on a Windstar in process of removing the motor
don't find many youtube videos on Windstar conversion have found 3 on
VW bus conversion though.
I'd be interested in how your conversion goes

[Alcibiades Ramos]

What I like about the Ford Aerostar is that it has a chassis, shares parts with the Ford Ranger and there's ample room for the batteries both below and above.
About the motor it's Vulcan on mine ...almost 200K miles on it. They never break so that's why the don't make it anymore lol but, it has to go. I am looking for a two speed gearbox but if I can't find one cheap I'll change the ring and pinion to a 3.08 and trade the pickup speed.

[Alcibiades Ramos]

I'm looking at the diagram for this generator and there are 2 Red 1 Black and 1 White wires coming out of the actual generator. Following the White wire (which changes opposite color) I get the impression it's the common wire for both 120v and 240v. Same for the Black wire coming out of the generator.
Now if you have 240v on what seems to be a Y array and that is already 2 phases right there, wouldn't the other wire conform for the 3rd phase? I am hoping it is.

All that said the thingy has 4 stars indicating that there was a couple of guys that had a very bad experience with it as a generator... something to think about.
In any case, were I to buy this it would have to be pulled apart to secure the coils and make sure isolation is not going to blow up on the first surge.

Last thing, I was wondering if you would be interested in bartering LiFePo's pouch cells for a PCB and some of the items.
Ooops... I said "last thing" and there's something else I wanted to ask you he he. Are you making provisions for oil cooling on the heat sinks? That will definitely give you an edge not only as far as power but also for the safety of the elements.
Tha... Tha... That's all Folks!

[sawickm]

Originally Posted by MPaulHolmes

I'm going to post all the stuff and you can definitely use it for a lower voltage and lower current application. It doesn't care about the voltage level used, or the current level.

Thanks for all your hard work !!!

-Mark

[adamj12b]

Originally Posted by Alcibiades Ramos

I'm looking at the diagram for this generator and there are 2 Red 1 Black and 1 White wires coming out of the actual generator. Following the White wire (which changes opposite color) I get the impression it's the common wire for both 120v and 240v. Same for the Black wire coming out of the generator.
Now if you have 240v on what seems to be a Y array and that is already 2 phases right there, wouldn't the other wire conform for the 3rd phase? I am hoping it is.

All that said the thingy has 4 stars indicating that there was a couple of guys that had a very bad experience with it as a generator... something to think about.
In any case, were I to buy this it would have to be pulled apart to secure the coils and make sure isolation is not going to blow up on the first surge.

Last thing, I was wondering if you would be interested in bartering LiFePo's pouch cells for a PCB and some of the items.
Ooops... I said "last thing" and there's something else I wanted to ask you he he. Are you making provisions for oil cooling on the heat sinks? That will definitely give you an edge not only as far as power but also for the safety of the elements.
Tha... Tha... That's all Folks!

I would not continue down the path of trying to use this motor.

First, you will have to overcome the field excitement circuitry, which might not be a big deal.

BUT, look at the specs....The motor is rated for 10kW surge... Even if you did turn it into a motor somehow, it would not have the power or overload ability needed to propel an EV. The wiring inside the generator will be severely undersized to carry even 100A.

I would suggest looking for another motor.

-Adam

[Alcibiades Ramos]

Thanks Adam, I was afraid that was the case with this generator but, you are right this generator is very far away from an H rating required for longevity. Back to the hunt.
A couple of AC-50 from Hi Performance Electric Vehicles would be fantastic but, they made a deal with Curtis and they will not sell you the motor without the Curtis 1238-7601 controller.
So I am open to suggestions. I have a limited budget, a whole bunch of ideas and a firm desire (call it commitment) to demonstrate one can get a decent AC drive for less than $5K's. As it is the AC-50 is $4300 plus shipping so that would leave no budget for the cells which are going to be LiFePo.

Alcibiades

[Alcibiades Ramos]

I adhere to that. Thanks Paul! Now hurry, my soldering gun ready to burn "me" fingers and I to blow up circuit! He he!

[Alcibiades Ramos]

Here is a 3 phase that delivers 132Kw for $100.00 plus shipping.

MS series aluminum housing 3 phase ac motor products, buy MS series aluminum housing 3 phase ac motor products from alibaba.com

So I'm thinking, no one builds anything in the US anymore? I mean look at the rotor and the poles, that thing has probably the efficiency of an IC engine.

[chapper]

Ben...
When you get near that Laser "etcher" again and have the time, try removing some copper from a piece of G-10 printed circuit material. For that matter, see if it will cut the stuff... and use an exhaust hood!
Thanks