Alternator Rewinding: Length & Gauge for 240V/20A & 15V/90A

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Discussion Overview

The discussion revolves around the process of rewinding an alternator, specifically focusing on determining the appropriate wire length and gauge for two different voltage and current scenarios: 240V at 20A and 15V at 90A. Participants explore the feasibility and complexities involved in this task.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • Rodney suggests that wire length affects maximum voltage and gauge affects maximum amperage, seeking formulas or tests to determine the necessary specifications for rewinding.
  • One participant expresses skepticism about the feasibility of rewinding alternators, noting that the process is complex and often more expensive than simply replacing the alternator.
  • This participant also mentions that rewinding would require expertise and that altering the voltage output would likely necessitate rewinding the rotor as well.
  • Another participant recommends a book titled "Alternator Secrets" as a potential resource for further information.
  • Rodney clarifies that the alternator in question is an older petrol alternator/generator, not a car alternator, which may have different considerations.

Areas of Agreement / Disagreement

Participants do not reach a consensus on the feasibility of rewinding the alternator, with some expressing doubts about the practicality of the task while others seek more information.

Contextual Notes

The discussion highlights the complexity of rewinding alternators and the potential need for specialized knowledge and tools, as well as the implications of altering voltage outputs.

rodnjo
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Hi,
I am looking at rewinding an alternator and have a few questions.
I believe that the length of the wire determines the max volts and the gauge determines the max amps. Is there a formula or some test I can do to determine the length and gauge I need the wire to be.

I have two scenarios:
240v 20amps
15v 90amps


Thanks in advance

Rodney
 
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No, I don't think it is reasonably possible to do this.

There are web sites that claim it is easy, though.
http://www.mtmscientific.com/rewind.html
for example.
Or this one:
http://simplewindalternator.info/can-i-rewind-a-95-mustang-alternator-to-charge-a-144v-electric-car-main-battery/

These days, rewinding alternators just to fix them has become so expensive and requires so much expertise, that it is usually cheaper to fit a new alternator. Getting one to operate on voltages it was never meant to work on would seem pretty hopeless unless you were already someone who could rewind alternators.

Also, these devices are wound in a very complex manner and unless you can supply 12 volts to your final product, you would also have to rewind the rotor. These have windings on them that depend on the wire being very thick to hold them in position.

One remote possibility, and I haven't tried this, is to get to the AC output before it gets to the diodes and try to transform this to a higher voltage with a transformer.
 
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Look for a book entitled: Alternator Secrets. Not sure who the author is, I just recall the title.
 
Hi,
Thanks for the replies.
I will have a look at those sites and the book. It's not a car alternator though, it's an older petrol alternator / generator.


Thanks'

Rodney
 

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