For anyone involved in the construction of small electric vehicles it has become a matter of great interest that a cheap high-power electric motor can be made from a humble car alternator. It’s a conversion made possible by the advent of affordable three-phase motor controllers, and it’s well showcased by [austiwawa]’s electric bicycle build video (embedded below).
The bike itself is a straightforward conversion in which the motor powers the rear wheel via an extra sprocket. He tried a centrifugal clutch with limited success, but removed it for the final version. Where the interest lies in this build is in his examination of Hall effect sensor placement.
Most alternator conversions work without sensors, though for better control it’s worth adding these magnetic sensors to allow the controller to more directly sense the rotation. He initially placed them at the top of the stator coils and found them to be ineffectual, with the big discovery coming when he looked at the rotor. The electromagnet in the rotor on a car alternator has triangular poles with the field concentrated in the centre of the stator, thus a move of the sensors to half way down the stator solved the problem. Something to note, for anyone converting an alternator.
For some people, mowing the lawn is a dreaded chore that leads to thoughts of pouring a concrete slab over the yard and painting it green. Others see it as the perfect occasion to spend a sunny afternoon outside. And then there are those without the luxury of having a preference on the subject in the first place. [elliotmade] for example has a friend who’s sitting in a wheelchair, and would normally have to rely on others to maintain his lawn and form an opinion on the enjoyability of the task. So to retain his friend’s independence, he decided to build him a remote-controlled lawn mower.
After putting together an initial proof of concept that’s been successfully in use for a few years now, [elliotmade] saw some room for improvement and thought it was time for an upgrade. Liberating the drive section of an electric wheelchair, he welded a frame around it to house the battery and the mower itself, and added an alternator to charge the battery directly from the mower’s engine. An RC receiver that connects to the motor driver is controlled by an Arduino, as well as a pair of relays to switch both the ignition and an electric starter that eliminates the need for cord pulling. Topping it off with a camera, the garden chores are now comfortably tackled from a distance, without any issues of depth perception.
Remote-controlling a sharp-bladed machine most certainly requires a few additional safety considerations, and it seems that [elliotmade] thought this out pretty well, so failure on any of the involved parts won’t have fatal consequences. However, judging from the demo video embedded after break, the garden in question might not be the best environment to turn this into a GPS-assisted, autonomous mower in the future. But then again, RC vehicles are fun as they are, regardless of their shape or size.
The humble automotive alternator hides an interesting secret. Known as the part that converts power from internal combustion into the electricity needed to run everything else, they can also themselves be used as an electric motor.
The schematic of a simple automotive alternator, from US patent 3329841A filed in 1963 for Robert Bosch GmbH.
These devices almost always take the form of a 3-phase alternator with the magnetic component supplied by an electromagnet on the rotor, and come with a rectifier and regulator pack to convert the higher AC voltage to 12V for the car electrical systems. Internally they have three connections to the stator coils which appear to be universally wired in a delta configuration, and a pair of connections to a set of brushes supplying the rotor coils through a set of slip rings. They have a surprisingly high capacity, and estimates put their capabilities as motors in the several horsepower. Best of all they are readily available second-hand and also surprisingly cheap, the Ford Focus unit shown here came from an eBay car breaker and cost only £15 (about $20).
We already hear you shouting “Why?!” at your magical internet device as you read this. Let’s jump into that.
There are probably times in every Hackaday reader’s life at which you see something and realise that the technology behind it is something you have always taken for granted but have never considered quite how it works. Where this is being written there was such a moment at the weekend, an acquaintance on an amateur radio field day posted a picture of three portable gas-powered alternators connected together and running in synchronization. In this case the alternators in question were fancy new ones with automatic electronic synchronization built-in, but it left the question: how do they do that? How do they connect a new power station to the grid, and bring it into synchronization with the line? There followed a casual web search, which in turn led to the video below the break of a bench-top demonstration.
If two AC sources are to be connected together to form a grid, they must match each other exactly in frequency, phase, and voltage. To not do so would be to risk excessive currents between the sources, which could damage them and the grid infrastructure. The video below from [BTCInstrumentation] demonstrates in the simplest form how the frequencies of two alternators can be matched, by measuring the frequency difference between them and adjusting their speed and thus frequency until they can be connected. In the video he uses neon bulbs which flash at the difference frequency between the two alternators, and demonstrates adjusting the speed of one until the bulbs are extinguished. The two alternators can then be connected, and will then act together to keep themselves in synchronization. There are further videos in which he shows us the same process using a strobe light, then demonstrates the alternators keeping themselves synchronized, and phase deviation between them.
Of course, utility employees probably do not spend their time gazing at flashing neon bulbs to sync their power stations. The same measurements are not performed by eye but by electromechanical or electronic systems with automatic control of the contactors, just as they are in the fancy electronic alternator mentioned earlier. But most of us have probably never had to think about synchronizing a set of alternators, so to see it demonstrated in such a simple manner should fill a knowledge gap even if it’s one only of idle curiosity.
Growing up in the 70s and 80s, a go-kart was a quick ticket to coolness, second maybe to a mini-bike. In both cases, a welded steel tube frame and a cast-off lawnmower engine were all that stood between you and neighborhood glory. Looks like a couple of engineering students caught the retro juvenile delinquent bug and built this electric go-kart for their final project.
While the frame for [Adrian Georgescu] and [Masoud Johnson]’s build was a second-hand find, the powertrain is all custom. They targeted a power output of 3 kW but found no affordable motors in that range. So, in true hacker fashion, they rolled their own motor from a used Subaru alternator. The three-phase motor controller came from an electric scooter, three LiPo packs provide the juice, and a pair of Arduinos takes care of throttle control, speed sensing, and sending data to the virtual dashboard on an Android phone. Some lights and a snappy red and black paint job finished off the build. While the video below shows that the acceleration isn’t exactly neck-snapping in the Tesla style, the e-kart can build up to a good speed – 53 km/h. Not too shabby, and no deafening engine right behind your head.
The laptop I’m using, found for 50 bucks in the junk bins of Akihabara has a CPU that runs at 2.53GHz. Two billion five hundred and thirty million times every second electrons systematically briefly pulse. To the human mind this is unimaginable, yet two hundred years ago humanity had no knowledge of electrical oscillations at all.
There were clear natural sources of oscillation of course, the sun perhaps the clearest of all. The Pythagoreans first proposed that the earth’s rotation caused the suns daily cycle. Their system was more esoteric and complex than the truth as we now know it and included a postulated Counter-Earth, lying unseen behind a central fire. Regardless of the errors their theory contained, a central link was made between rotation and oscillation.
And rotational motion was exploited in early electrical oscillators. Both alternators, similar to those in use today, and more esoteric devices like the interrupter. Developed by Charles Page in 1838, the interrupter used rocking or rotational motion to dip a wire into a mercury bath periodically breaking a circuit to produce a simple oscillation.
As we progressed toward industrial electrical generators, alternating current became common. But higher and higher frequencies were also required for radio transmitters. The first transmitters had used spark gaps. These simple transmitters used a DC supply to charge a capacitor until it reached the breakdown voltage of the gap between two pieces of wire. The electricity then ionized the air molecules in the gap. Thus allowing current to flow, quickly discharging the capacitor. The capacitor charged again, allowing the process to repeat.
As you can see and hear in the video above spark gaps produce a noisy, far from sinusoidal output. So for more efficient oscillations, engineers again resorted to rotation.
The Alexanderson alternator uses a wheel on which hundreds of slots are cut. This wheel is placed between two coils. One coil, powered by a direct current, produces a magnetic field inducing a current in the second. The slotted disc, periodically cutting this field, produces an alternating current. Alexanderson alternators were used to generate frequencies of 15 to 30 KHz, mostly for naval applications. Amazingly one Alexanderson alternator remained in service until 1996, and is still kept in working condition.
A similar principal was used in the Hammond organ. You may not know the name, but you’ll recognize the sound of this early electronic instrument:
The Hammond organ used a series of tone wheels and pickups. The pickups consist of a coil and magnet. In order to produce a tone the pickup is pushed toward a rotating wheel which has bumps on its surface. These are similar to the slots of the Alexanderson Alternator, and effectively modulate the field between the magnet and the coil to produce a tone.
Amplifying the Oscillation
The operation of a tank circuit (from wikipedia)
So far we have purely relied on electromechanical techniques, however amplification is key to all modern oscillators, for which of course you require active devices. The simplest of these uses an inductor and capacitor to form a tank circuit. In a tank circuit energy sloshes back and forth between an inductor and capacitor. Without amplification, losses will cause the oscillation to quickly die out. However by introducing amplification (such as in the Colpitts oscillator) the process can be kept going indefinitely.
Oscillator stability is important in many applications such as radio transmission. Better oscillators allow transmissions to be packed more closely on the spectrum without fear that they might drift and overlap. So the quest for better, more stable oscillators continued. Thus the crystal oscillator was discovered, and productionized. This was a monumental effort.
Producing Crystal Oscillators
The video below shows a typical process used in the 1940s for the production of crystal oscillators:
Natural quartz crystals mined in Brazil were shipped to the US, and processed. I counted a total of 13 non-trivial machining/etching steps and 16 measurement steps (including rigorous quality control). Many of these quite advanced, such as the alignment of the crystal under an X-Ray using a technique similar to X-Ray crystalography.
These days our crystal oscillator production process is more advanced. Since the 1970s crystal oscillators have been fabricated in a photolithographic process. In order to further stabilize the crystal additional techniques such as temperature compensation (TCXO) or operating the crystal at a temperature controlled by the use of a heating element (OCXO) have been employed. For most applications this has proved accurate enough… Not accurate enough however for the timenuts.
Timenuts Use Atoms
Typical timenut wearing atomic wristwatch
For timenuts there is no “accurate enough”. These hackers strive to create the most accurate timing systems they can, which all of course rely on the most accurate oscillator they can devise.
Many timenuts rely on atomic clocks to make their measurements. Atomic clocks are an order of magnitude more precise than even the best temperature controlled crystal oscillators.
Bill Hammack has a great video describing the operation of a cesium beam oscillator. The fundamental process is shown in the image below. The crux is that cesium gas exists in two energy states, which can be separated under a magnetic field. The low energy atoms are exposed to a radiation source, the wavelength of which is determined by a crystal oscillator. Only a wavelength of exactly 9,192,631,770Hz will convert the low energy cesium atoms to the high energy form. The high energy atoms are directed toward a detector, the output of which is used to discipline the crystal oscillator, such that if the frequency of the oscillator drifts and the cesium atoms are no longer directed toward the detector its output is nudged toward the correct value. Thus a basic physical constant is used to calibrate the atomic clock.
The basic operating principle of a cesium atomic clock
While cesium standards are the most accurate oscillators known, Rubidium oscillators (another “atomic” clock) also provide an accurate and relatively cheap option for many timenuts. The price of these oscillators has been driven down due to volume production for the telecoms industry (they are key to GSM and other mobile radio systems) and they are now readily available on eBay.
With accurate time pieces in hand timenuts have performed a number of interesting experiments. To my mind the most interesting of these is measuring time differences due to relativistic effects. As is the case with one timenut who took his family and a car full of atomic clocks up Mt. Rainier for the weekend. When he returned he was able to measure a 20 nanosecond difference between the clocks he took on the trip and those he left at home. This time dilation effect was almost exactly as predicted by the theory of relativity. An impressive result and an amazing family outing!
It’s amazing to think that when Einstein proposed the theory of special relatively in 1905, even primitive crystal oscillators would not have been available. Spark gap, and Alexanderson alternators would still have been in everyday use. I doubt he could imagine that one day the fruits of his theory would be confirmed by one man, on a road trip with his kids as a weekend hobby project. Hackers of the world, rejoice.
[Glenn] from The Back Shed has built a lot of windmills and stationary generators over the years, but recently decided to try his hand at building something a bit more portable.
The charger is based of a relatively simple design, employing a 5.2 HP Kubota 4 stroke motor and a 12v car alternator to provide power. While you might be inclined to point out that his charger does exactly what an alternator and motor are built to do, there was a bit more to it than simply slapping the two parts together.
A laser cut adapter plate holds the motor and alternator together, but once [Glenn] wrapped things up and gave the motor a spin, he realized that he was driving the alternator backwards. This would eventually cause the alternator to overheat since the cooling fan was running the wrong way. He removed the fan and reversed the fins with a hammer so that he could get the cooling he needed without having to reinstall the alternator in the opposite orientation.
The whole kit was mounted on a hand truck for portability, and [Glenn] says that the charger/generator only needs to run about 5 minutes before a dead battery has enough juice to crank an engine.
