How to make a powerful motor from a car generator

Somehow I got an old but working generator. I decided to convert it into a BLDC motor. In the future I will use it for a homemade electric bicycle or electric scooter. In general, the motor is suitable wherever a variable electric drive is required.
How to make a powerful motor from a car generator

Materials used


  • car generator;
  • solder;
  • copper wires;
  • battery;
  • control board with speed controller.

Tool: ratchet with extension and set of sockets; screwdrivers; hammer; narrow nose pliers; bearing puller; wire cutters; stationery knife; soldering iron

The process of converting a generator into a BLDC engine


We take the car generator and begin to disassemble it.
How to make a powerful motor from a car generator

First of all, unscrew the nuts that hold the back cover with the bearing.
How to make a powerful motor from a car generator

Remove the brush assembly.
How to make a powerful motor from a car generator

Unscrew the pulley mount and remove it.
How to make a powerful motor from a car generator

We take out the key.
How to make a powerful motor from a car generator

Remove the front cover of the generator.
How to make a powerful motor from a car generator

We take out the rotor.
How to make a powerful motor from a car generator

We unscrew the fastenings of the stator winding leads from the rectifier diode block.
How to make a powerful motor from a car generator

Disconnect the stator from the back cover.
How to make a powerful motor from a car generator

Unscrew the fastenings of the diode bridge and remove it.
How to make a powerful motor from a car generator

We clear the conclusions. We connect the stator winding according to the "triangle" diagram.
How to make a powerful motor from a car generator

Solder the wires to the terminals.
How to make a powerful motor from a car generator

Take the removed brush assembly. Its design includes a voltage regulator. It needs to be disconnected.
How to make a powerful motor from a car generator

We solder the wires to the brushes, bypassing the voltage regulator.
How to make a powerful motor from a car generator

Reassemble the engine in reverse order. If necessary, we change the bearings and grind the slip rings.
How to make a powerful motor from a car generator

We connect the rotor winding to the power supply. The stator outputs are connected to the control board. The driver itself is powered from the battery.
How to make a powerful motor from a car generator

Using a regulator, which can be a regular potentiometer, we adjust the speed of the BLDC motor.
How to make a powerful motor from a car generator

Useful tips


The BLDC motor obtained in this way has insufficiently good efficiency, since energy is spent in the field winding to bias the rotor. This drawback can be eliminated by installing neodymium magnets.
I took a driver that works without a Hall sensor. It's cheaper and quite suitable. If you want to get good performance, you can put a Hall sensor in the motor and connect it to the appropriate board.
Before connecting the motor to the battery, be sure to check the windings for interturn short circuit and breakdown to the housing.

Watch the video


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Comments (7)
  1. Novel
    #1 Novel Guests 12 March 2020 15:53
    5
    BLDC - BrushLess DC (Brushless DC Motor). What kind of brushless one do you have? Learn materiel. So-so article...
    1. Druid 02
      #2 Druid 02 Guests 14 March 2020 22:25
      2
      No one said anything about without a brush. But everything is real.
  2. Andrew
    #3 Andrew Guests 13 March 2020 18:27
    3
    alternating current generator, simply with a rectifier. does the driver "give birth" to the variable?
  3. Andrew
    #4 Andrew Guests 13 March 2020 18:30
    3
    The winding is already on the star! what triangle?
  4. Grandfather Sasha
    #5 Grandfather Sasha Guests March 17, 2020 00:17
    2
    I can't believe it! It will spin, but the power... I assume that it is at least 1 order of magnitude lower than that of the original generator
  5. u841so
    #6 u841so Guests 18 March 2020 16:02
    1
    from the category of “how to make a jigsaw out of a washing machine”!

    or how to get a non-thing out of a thing
    for what is born should not spin.
  6. Basil.
    #7 Basil. Guests 15 December 2020 15:48
    3
    It should and will spin. If you don’t want to believe it, check it yourself. The idea is not new, but it works and is not bad. The efficiency is not high, but no one promised it.