Alternator converted to a motor driving a high-speed turbine water pump.

Alternator Conversions
How to Convert an Alternator to A Motor.

A Low Cost Alternative to A High-Power Brushless Motor.

A Car Alternator Can Be Made Into A Powerful Hybrid Brushless Motor In A Couple Hours With Common Tools.

See streaming videos below of converted car alternators driving a high-capacity water pump and a 2.8 Horsepower (HP) Dynamometer Load.

Use for electric vehicles, robotics, industrial, alternative energy, experimental electric aircraft, and automotive applications.

Larger alternators converted to motors from buses, trucks, boats, and aircraft may produce significantly more power.

Click for Alternator Speed-Torque Curves, Speed-Power Curves, and Performance Data.

The videos below show a small car alternator from a Chevrolet Camaro powering a water pump and a dynamometer test load.

In the above video:
  1. A small alternator from a Chevrolet Camaro has been converted to a motor.
  2. The alternator speed is 3270 RPM, and it is driving a dual-output water pump with an output of 22 gallons per minute.
  3. The alternator output is approximately 0.40 HP as shown in the video. When both output tubes are 90% blocked (not shown in video) creating back-pressure, the alternator output power is approximately 0.75HP.

The video below shows a higher power application.

In this video, a small alternator is tested to see how much power it can output with a maximum current limited to 100 Amps:
  1. An alternator dynamometer test is performed to measure the net mechanical output power of an alternator converted to a motor.
  2. The alternator on the right has been converted to a motor. This is the same alternator (Chevrolet Camaro) as in the first video.
  3. The alternator on the left is used as a conventional alternator to generate electricity.
  4. The alternator motor on the right drives the conventional alternator on the left (belt drive), which generates electricity. The alternator on the left loads down the alternator on the right by acting as a dynamometer load ("Dyno") by generating electricity which is dissipated in a resistive electrical test load.
  5. The sequence in this video:
    1. Video starts by showing alternator converted to motor (right side) running at 5200 RPM with no load.
    2. Next, the load is increased to 2.8 HP in 3 steps, then back to light load in 3 steps. (Again, the load is provided by the conventional alternator on the left generating electricity.)
    3. Next, the load is abruptly raised from zero (no load) to 2.8 HP. The alternator speed drops from 5200 RPM to 2800 RPM from this load. The alternator speed drops because the current is limited to 100 Amps.
    4. Next, the 2.8 HP load is abruptly removed, and the speed increases from 2800 RPM to 5200 RPM.
    5. This sequence is repeated one more time.

An alternator converted to a Hybrid Brushless Motor provides a low-cost alternative to brushless motors (BLDC) because alternators are mass-produced way beyond the quantities of brushless motors, and they have dynamic behavior similar to brushless motors in a wide range of applications.

China has effectively cornered the market on the key ingredient of brushless motors -- rare earth metals, which are used for the permanent magnets in a brushless motor (BLDC), so brushless motor prices keep increasing.

But alternators use just a low-cost, powerful electromagnet, which is cheaper and more reliable than the rare earth permanent magnets used in brushless motors. The electromagnet is more reliable because it is not subject to demagnetization, and it does not have the risk of flying off the rotor at high speeds like rare earth permanent magnets used in BLDC motors.

And alternators are readily available worldwide -- as close as the nearest auto parts store or junk yard.

What is a Hybrid Brushless Motor?

All power drive current to this motor is brushless: drive current passes only through the stator and does not go through any brushes. Only a small field current passes through brushes and smooth slip rings to the rotor. This is a highly reliable design with minimal abrasion (unlike commutators in conventional dc motors), which is typically used for resolvers and synchros on aircraft, and high-reliability industrial applications. This is called a Hybrid Brushless Motor since it has a combination of brushless power drive current and a small brushed field current.

This Hybrid Brushless Motor is functionally very similar to a conventional brushless motor except that it has an adjustable field, unlike a conventional brushless motor, which has a fixed field. This field is adjusted by applying a small dc current, typically 0.5A – 4.0A. This can give better performance than a conventional brushless motor by producing full torque at BOTH low speeds and high speeds, compared to a conventional brushless motor which tends to lose torque at high speeds.

An automotive alternator converted to a motor can exceed the performance of both brushed and conventional brushless motors because of the combination of its brushless drive current and adjustable field. A car alternator changed over to a motor can put out in excess of 1.0 HP -- in many applications far above that, depending on the alternator, how it's converted, and how it's controlled.

An automotive alternator converted to a motor is much less expensive than a conventional brushless motor with the same power output. A car alternator that can be readily converted to a powerful motor costs about $100.00, but a conventional brushless motor that produces about the same power output typically costs far more -- well over $500.00 and is often more difficult to obtain with long order lead times.

In addition, a car alternator functioning as a motor has more versatile control than a conventional brushless motor, and it can have more power and torque at high speeds than a conventional brushless motor of similar size due to its adjustable field.

Our Alternator Conversion Manual, "How to Convert an Automotive Alternator to a Hybrid Brushless Motor" shows in clear step-by-step instructions with photographs how to do the conversion. It also explains how to drive the alternator as a motor. It includes common-sense explanations of how the converted alternator functions as a motor with clear, easy-to-read diagrams.

Alternator Conversion Manual
After reading our how-to guide, you will be able to convert a car alternator into a powerful, reliable, and low-cost Hybrid Brushless Motor using low-cost, common tools, and you will understand how this new motor works and the advantages this new motor has over conventional brush and brushless motors.

(Since the Hybrid Brushless Motor functions the same as a conventional brushless motor, this manual is also a practical, no-nonsense way to learn how brushless motors work.)

What can you use this Hybrid Brushless Motor for? -- anywhere a powerful, low-cost, high-reliability motor can be used: industrial, electric vehicles, alternative energy applications (converting gasoline, diesel, pneumatic, and hydraulic machinery and equipment to electric) robotics, model aircraft, scientific, automotive, aircraft, marine, and scores of related applications.

Alternator Conversion Manual

This provides a reliable and low-cost alternative to high-power brushless motors for many applications which is easily acquired and second-sourced.

With over 25 years in high-tech industrial and aircraft power system development, put our know-how to work for your innovative projects.

Alternator Conversion Manual for Download......

$19.95 ITEM 5-4F-RW

Alternator Conversion Manual Hardcopy.

$24.95 ITEM 5-4-RW