CONVERTING
A JUNKYARD AUTOMOTIVE ALTERNATOR INTO AN EFFICIENT ALTERNATIVE
ENERGY PERMANENT MAGNET ALTERNATOR
You do not need to machine anything,
nor do you need to wind your own coils or purchase any expensive
magnet wire.
And no, you do not have to worry
about stray induction or eddy currents damping out the energy
production or causing inefficiencies. All you have to do is
go to a pull-it-yourself junkyard and find the largest automotive
alternator (in Ampere rating) you can find. If you have a
very small prime mover energy source to tap, do not go too
big, or you will not have the power required to turn the permanent
magnet alternator. Also, the higher the amps, the higher the
"E Squared losses".
(Power =electromotive force squared
divided by resistance, or Power equals voltage in volts squared
divided by resistance in ohms of the windings) Some mechanical
energy input is required at the shaft to overcome the E-squared
losses in the stator coil windings before any excess power
can be produced or removed from the alternator.
(Where I am in Richmond VA ,
junkyard alternators cost about 10-15 bucks each and are readily
available.)
Automotive alternator
exploded view
The only part that needs to me modified is item 1, called
the rotor.
BASIC CONSTRUCTION
THE (SIX POLE) CLAW POLE ROTOR DESIGN
PRODUCES 12 ALTERNATIONS IN THE MAGNETIC FIELD PER ROTATION
PER SHAFT ROTATION, ALLOWING MUCH SLOWER SHAFT SPEED TO SUFFICIENTLY
PRODUCE THE REQUIRED MAGNETIC FIELD "ALTERNATIONS"
A
modern alternator contains both moving and stationary coils
of wire. In the alternator, however, the moving coil, called
the rotor, uses current supplied through slip rings to generate
a moving field. Power is extracted from the stationary field
coils.
To
convert to permanent magnet, the claw shaped pole pieces
of the rotor need only be removed from the shaft temporarily
and the rotor coil, a donut shaped coil of wire is then
discarded along with the carbon brushes and slip rings.
The rotor coil is simply replaced with the strongest available
donut magnet of equal size to the rotor coil. The magnetic
field in the donut magnet must be aligned so that the flat
ends of the donut cylinder are North and south poles.
In the picture above,
of the two blue claw-pole rotor pole pieces (with the shaft
removed) can be seen nested in their normal operating position
within a cutaway view of the power producing three phase
stator coils. Note the orange donut shaped powerful permanent
magnet that now replaces the old electromagnet coil sandwiched
between the two claw shaped rotor pole pieces.
A hydraulic bench press will be required
to press the pole pieces off and then back on the shaft,
after the rotor coil is replaced with a powerful permanent
donut magnet. An experienced motor electric re-builder shop
should be consulted to teach you how to do this without
deforming and ruining the pole pieces. It is very important
to get a tight fit on the shaft so that both claw-poles
are snug against the magnet. Wetting the ends of the magnet
with ferro-fluid can help here, by forming a trapped magnetically
conductive layer that fills any slight surface irregularities
to maximize the magnetic force of the rotor assembly.
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