electrical engeeners and others HELP

wilson ind

Well-known Member
Thinking strongly about building an another electric truck or tractor. My major problem is charging 48 volt system as a hybrid unit. Some may recall my electric pickup from farm show. It worked well in some aspects. I would like to add a hybrid aspect. What I need is how to either regulate common Delco automotive alternator to 48 volt output, or regulate a surplus starter generator 30 volt to 48 volt. According to all research no problem on either unit with the voltage. I just need to regulate the output. My truck worked well for close range, however I want to use internal combustion power to supplement the range. Thanks to all who respond with knowledge. I am willing to pay fairly for engineering help.
 
Not an engineer, but I don't see a common automotive alternator having enough output to do what you expect.

As the voltage goes up, the amperage goes down. Example, a 100a alternator @12v, becomes a 25a alternator at 48v. You would need multiple alternators, or one large alternator from another source. Then the engine would need to be sized for maximum economy.

It would take a lot of research, but what about repurposing a hybrid car? At least most of the components would be sized accordingly. Just have to get inside it's brain and stir it around! Just a thought...
 
The leece-neville 110-555JHO can be modified to approach 48v as they support an external voltage regulator, you would have to increase the speed it spins dramatically. If you look around on some of the DIY wind/solar forums you can find some similar setups.
 
The design of an alternator is self limiting in output. They do not put out more amps than they are designed to put out. This is due to self reactivity as the power goes up the Current in the stator windings repels the rotor magnetism and won't burn up from excess power. That is why they do not need current limiting circuitry in the regulator. This is independent of voltage! The defrosting alternators from mid 60s Thunderbirds were in the hundreds of volts 3phase. Used to warm the glass which had gold film in it. Jim
 
You are correct, now I need to find one such alternator. Early this morning thanks to the internet there is a 48 volt regulator for the leece_-Neville. Thank you.
 
Thank you. I left a message for old friend John T EE but no response yet. He is what he called MOOCH CAMPING as he is homeless due to buyer wanting possession. Old John T is smart. Take the money when it's offered. LOL
 
From experience I can tell you that common automotive alternators do not like to be run at their rated output continuously. It's not clear if that is what you have in mind, or if you are looking at some sort of industrial alternator for your application.

With automotive alternators you will probably want to run multiple alternators at partial output to get any sort of reliability.

Telephone communications switching equipment is 48VDC. You might be able to adapt some surplus telecom equipment and have a "genset" application rather than a hybrid.
 
Thank you. Have a good friend retired from ATT. He may have contacts on finding more info and locating used equipment.
 
Some Cushman electric vehicles carry on board battery chargers. Plug in the charger whenever the vehicle is parked. On electric fork trucks we swapped out the battery packs to keep the fork trucks moving.

Could you mount an off-the-shelf portable generator on your vehicle to power an on board charger? I would look for a genset with a continuous duty rating at least 25 percent larger than the charger input.
 
(quoted from post at 21:04:56 11/13/17) Thinking strongly about building an another electric truck or tractor. My major problem is charging 48 volt system as a hybrid unit. Some may recall my electric pickup from farm show. It worked well in some aspects. I would like to add a hybrid aspect. What I need is how to either regulate common Delco automotive alternator to 48 volt output, or regulate a surplus starter generator 30 volt to 48 volt. According to all research no problem on either unit with the voltage. I just need to regulate the output. My truck worked well for close range, however I want to use internal combustion power to supplement the range. Thanks to all who respond with knowledge. I am willing to pay fairly for engineering help.

Just thinking out loud here.

I do not know what battery configuration you have.
Could you tap in to isolate half of the cells?

-Drive 2 24 volt alternators in tandem off the gas engine with each one charging half the battery bank.

-Or a single 24 volt alternator and a handful of diodes to do the same.
 
On most alternators, a person should be able to bring the rotor connections outside the case so an external regulator can be used. Need to verify if type A or B rotor if both connection can not be isolated.
 
Several years ago there were books available to convert a regulator to 24 or 48 volts, one method that was discussed was tapping the series string at 12 v for the regulator and using the output to charge the whole string. I do not remember the details but the book was on modifications to alternators for off grid use.
 

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