Yes I realise there are a few threads regarding the use of alternators to create a motor. They can be found (at least the 2 best ones) here
. They have some good general information but neither actually appear to deal with converting the motor itself. Not that there is much to do, but I will be going to a greater level of customisation than it’s probably worth. But hey – I’m like that.
I plan to someday (in the reasonably near future) convert a car into a track EV monster. But having had no prior experience with electric motors at all I don’t want to start totally un-prepared. OTS the shelf is all well and good but it doesn’t challenge me enough. I’m a tinkerer, I like hands on. I feel this is a good way to get the ball rolling. Besides, it may turn out to be useful for something!
What I hope will make this thread a worthwhile read is that I intend to record my efforts in actually converting an alternator into a permanent magnet (PM) motor - that is replace the stock ‘claw’ rotor with a custom made PM magnet rotor instead. I also want to gut out the unimportant pieces, clean up the left over parts, modify the housing and if the benefits can be justified possibly rewind the stator.
I will use this thread to show people what I’m doing and to ask questions of people in the know. Hopefully this will keep the relevant questions and answers in one easy to find place instead of spread over 50+ threads. Makes sense in my head anyway!
Enough rambling and onto the ‘Altermotor’. I managed to score a 24V truck alternator off a friend for free. Other than those details that’s all I know. It’s been sitting on his work bench for who knows how long and is fairly dirty. In my sheer excitement to finally have one in my hands (I’ve been looking into doing this for a few months now but have been to busy) I forgot to take a photo before I did anything. But meh, it’s pretty unexciting. Here’s a photo of the whole thing apart in it’s primary peices:
It was taken with my phone so apologies for the photo quality. The rotor coil on the far right and the claw rotor on the far left (the rusty bit around the shiny axle) will both go. When I get the rotor claw off I will design a PM magnet holder that will slot straight into its place. The stator has 18 teeth (or coils) on it so I’ll be looking to fit 16 magnets (or 8 pole pairs) to the new rotor.
Anywho....my first questions:
1) My first port of call is a massive cleanup. Can anyone suggest a good cleaning agent that I can use on the stator/windings/everything else? Or is a rub down with a dry cloth the most I should do? I obviously don’t want to damage the insulation coatings on the laminations or coils...
2) I should also probably decide at this point whether a rewind is on the cards or not.It is currently wound with doubled stranded (as in 2 pieces of wire for one turn) of what I think (rough measurement using a ruler) is 18AWG wire. Thicker wire will obviously allow for higher currents but what are my chances of being able to wind a thicker strand? I’ve never done it before but I’m willing to put in the time and effort. I have read Thuds rewind thread but that's fairly motor specific...
So yeah, I’ll leave it there for now I think. Thanks for reading and any information to my questions above, or general comments, insults and jokes about my little project would be greatly appreciated.