Dane.Kouttron
ATOMO: The Electric Bike Project
| Build Process for converting an Alternator into a 3 phase Perm Magnet Brushless Motor. |
| Step # | Description | Details / Images |
| 1 Get a crufty alternator | Locate an alternator, scrap yards or wherever. | a 'random alternator' should run you 30 bucks if not free. |
| 2. Open the alternator | Chances are its rusty, use some sort of penetrant (liquid wrench / homebrew) |
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| 3.Remove Electronics | Basically the 'electronics' for the alternator is a 3 phase bridge rectifier and a device to modulate the field current based upon alternator loading. remove it, there should be 3 inputs going to it. | CUT OUT THE PLASTIC ELECTRONICS BOARD ITS NOT HARD |
| 4. Attach three phase outbound cables | There should be 3 or 4 wires coming from the alternator (wye or delta configuration, where wye has the centertap connected). either work perfectly, assuming you can build a 3 phase motor drive for either. |  |
| 5.
Make A new ROTOR [Take measurements] |
ok, so you've got a beautiful 36 pole motor winding assembly, and you want to make a 12 pole rotor: crank up solidworks, do some cad'ing and make some measurements. you want to use an iron or other permeable material. no aluminum. |  |
| 6. Order some magnets | go
here: http://www.supermagnetman.net/Sindex.php |
Find a good magnet for your sized rotor. note the 12:36 ratio works really well. (36 poles, 12 magnets) im using 1/4* 1/2 * 1.5" N40 magnets. sufficient strength for this purpose |
| 7. match and wrap motor core | Documentation will be added shortly | Documentation will be added shortly |
Dane.Kouttron
Rensselaer Polytechnic Institute
Electrical & Electrical Power
631.978.1650
