Overhaulin'

Can I rewind a 95 Mustang Alternator to charge a 144v Electric Car main battery?

I've seen alternators, such as a prestolite 12v 140 amp, rewound with thinner gauge wire and with more winds and used as a regenerative brake (energized while coasting to use the car's forward motion to charge main battery pack) in electric vehicles. I was wondering if a 3G alternator from a 94-95 Mustang could be rewound the same way? What type of wire would I need to do this? What else, other than the actual stator rewinding, would need to be modified for this alternator to safely put out this high of voltage? Also, what effect would the original amp rating of the alternator have on the final result (they are available at 85, 130, 200, etc...)? For the below answer, although just another useless question: the regen brake is engaged by pressing the brake pedal (triggered by brake switch. Why would I need to turn off the ignitin in an electric vehicle?!? Also, it gets run from a belt and elected clutch. Been done b4 on cars, don't know why this would be any different. As for pre-existing parts: if I could find DC regen parts I'd look into them! As for

Public Comments

1. We have in a car alternator the circuitry to convert the AC power to DC and regulate its voltage. But if we strip that rectifier and voltage regulator out, we can connect the AC windings to an external transformer to convert to any voltage we want. Output from the transformer would be to a rectifier and so on to voltage regulator and battery pack. The alternator will still have a limited power, and you would likely want to be able to limit field coil current to prevent overload or over-voltage (no load situation) But just do the math, A `12 volt 140 amp alternator can put out under 2 kw continuously possibly surge to 3kW. Regenerative braking would require 20 kW to be effective. Now there are aircraft generators that kick out 500 amp 50 volts that would give 25 kW continuous with 40 kW surge. That is the scale of power you should have for a 1 ton car.
2. How do you propose the engage your homemade regenerative braking system, put the transmission in neutral ans cut the ignition? That would be dangerous and illegal, if ever had an accident while doing this, you'd be sued for all you are worth until you die.
3. yes you could rewind your alternator to do what you want, but why? why not buy the things you need that are already designed to do just what you want. it would save you a lot of time and effort,. unless you are skilled at rewinding armatures and field coils, you are better off buying.
4. first of all, you will need 172.8 volts for charging a 144 volt battery pack. alternators used in the auto industry made after 1986 are not a good choice for your application. I had a similar problem when I built my hybrid motorcycle. In my application, I needed to charge a 48 volt battery pack. The solution was to use an older style alternator from the late 60's to late 70's. These units were tough. Mine operates at 56 volts and gives up to 65 amps without burning up. Contact Electrodyne and see if they can help. Otherwise, I would suggest looking for a 180 volt 3hp or larger permanent magnet motor (DC current) and use it as a generator. You would have to use a 250 volt 50 amp diode inline to prevent current back-flow to the motor.
5. As it is an EV anyway - can't you use the drive motors? If you use flat plate type permanent magnet motors, they can act as motor or brake depending on how you control them. You could even have 4 extra flat plate motors directly as an output to an gas engine to supply extra power when needed.
6. The one EV car I currently have (have 2 vehicles that run on hydrogen also) I converted from a vw bug and is free to charge. As I live completely off the grid all my electricity comes from solar panels and 2 wind generators, which I also built. However I did charge up at Costco in Carlsbad California (I actually only drove up there to fill up) if I remember right it was around $2.00 Not sure if you’re interesting in doing it yourself, but I’d be willing to walk you step by step threw the conversion. I've converted 3 of my own cars (a datsun truck, ford ban, and a vw bug) and a few for neighbors. I've also converted cars to run on hydrogen, ethanol and biodiesel, by far EV is the easiest. If you’re interested here’s what it would entitle… - The engine compartment is first cleaned out of any gasoline components. - Electric components are then installed in exchange. - A battery bank is built and incorporated. - Existing starter and driving systems are connected. - Turn the key, step on the gas pedal sending more energy to the electric motor, & thus more power to the drive system, which in return creates more speed, more acceleration. - The system has normal automotive top speeds and acceleration, typical to the vehicle your modifying. If your top speed was 85 mph and your acceleration was 1 mile per min, then this will be what your left with after the conversion. The methods are extremely simple, making the process possible for anyone, everyone, ANYWHERE. Typical tools, hardware & supplies are used, making access to parts available for all. Electric Conversions can be easily accomplished in ANY model vehicle, even tractors, Generators, types of machinery, etc. Project lengths range from 1 day to 1 month. If you’re interested I wrote a guide on it which is available at www agua-luna com My last EV conversion ran me about $1400. Everything is available online. I have a how to do it yourself guide available at www agua-luna com that will walk you step by step through the process. If you have ANY questions feel free to contact me through the site. Here’s a list of what you'd need... Advanced DC Motor The motor is an 8" Advanced DC series-wound motor. It weighs 107 pounds and is rated at 68 peak horsepower. These motors are available in several sizes. Adaptor plate The adaptor plate mates the motor to the transmission. It is constructed of 1/2 inch aluminum and is pre-drilled with bolt hole patterns for both the motor and transmission. An aluminum spacer is also used for proper spacing between the shafts of the transmission and motor. Adaptor plates are available for many cars. DC Motor Controller The controller regulates current going to the motor. It is a solid-state device that uses a pulse width modulator (PWM) that sends short bursts of current to the motor at a rate of 15 kHz. Controllers are available from both Curtis and DCP. Potbox (Potentiometer) The potbox is a 5K ohm throttle between the controller and the accelerator, similar to the way a sewing machine pedal works. The potbox's lever arm is attached to the existing accelerator cable. Main Contactor An electric relay that serves the same purpose as the ignition switch in a gas car. When the key is turned to the start position, the contactor closes the circuit to allow current to flow to the controller. Circuit Breaker A safety device that shuts down power for servicing or during an emergency. The circuit breaker is installed under the hood and can be switched both off and on from the drivers seat with an extension or cable. Main Fuse The main fuse protect the system from high voltage spikes. A fuse should be installed at each battery box or group of batteries. Shunt A shunt is placed in series within the wiring as a means to connect meters. Shunts are available in different sizes for both high and low power configurations. Charger interlock A relay that keeps the circuit open so nobody will inadvertently drive off with the charge cord plugged into the car. DC/DC Converter The DC/DC converter is similar in function to a gas car's alternator. It charges the 12 volt accessory battery by chopping voltage from the main battery pack down to 13.5 volts. If you interested I offer several DIY alternative guides to walk you step by step threw EV conversion process at agua-luna com or www agua-luna com Hope this helped, feel free to contact me personally if you have any questions if you’d like assistance in making your first self sufficient steps, I’m willing to walk you step by step threw the process. I’ve written several how-to DIY guides available at www agua-luna com on the subject. I also offer online and on-site workshops, seminars and internships to help others help the environment. Dan Martin Alterative Energy / Sustainable Consultant, Living 100% on Alternative & Author of How One Simple Yet Incredibly Powerful Resource Is Transforming The Lives of Regular Peop
7. Not very practical . The wire would be small enough I would guess U might get 20 amps max . U would blow the diodes , and the regulator would need to be designed for the voltage.