How Alternator works + DIY Voltage Regulator

Taking Apart Engine: • Taking Apart Engine
I thought I had an idea about how this stuff worked, so I built this rig to see if I was right. I'm sure they use a more sophisticated voltage regulator but this proved the concept for me.
Get a cheap Arduino and play with it!: amzn.to/2iE9T8K
Many things were diluted into a basic conceptual understanding that I wanted to get across. Physicists and Engineers please don't be mad at me.
To see what I'm up to as it happens, follow me on / sammsheperd
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[@RegStefan]

a mechanic, electrician, machinist, and a computer tech?? what I'm doing w my life

[@kenzieeyy8508]

😞

[@HoustonALEE]

After reading this I have asked my self the same question and I hope you have been motivated to become the greatest that you are. Regardless of my past mistakes I am thankful I have been allowed to see beyond the waste for time left given.

[@HoustonALEE]

​@kenzieeyy8508 The first is a acknowledging. No worries friend for more than half have not arrived where you are. Do your best from this for if time you have been given feels not enough their is someone among your presence that if given a chance your time spent helping will bless their time and make yours forever become eternal.

[@paulwharton1850]

Amazing ! So great to watch - This 57 year old learnt a lot. Many thanks.......all the way from London.

[@benjamindover7399]

I'm impressed with the home made voltage regulator. you could have saved a lot of time getting one off the shelf but making your own shows great initiative and ingenuity.

[@FredFlintstone21]

Thank you for making this video. I kept pausing, writing down, going back, and will watch again a few more times. I bought a mint 81 rabbit diesel, it had a 55 amp motorola alternatir in it, I upgraded the stereo system, and put a single wire chevy alternator in there, that supposedly will put out 225 amps at higher throttle. My fuel mileage went from a consistant 51-53 mpg to 46-47 mpg with just the alternator change. I bought a fluke 325 amp clamp, turned everything up and on in the car and the amp clamp at higher rpms is reading 60 amps.

[@wbfog]

Absolutely fascinating! Advanced electrical, computer programming, and combustion engine all in one. I love this!

[@nabilmortada9082]

dude I love you problem solving skills ! one of the best DIY videos I watched Physics teacher here so yeah! I love your work :)

[@AdrianWhyte]

Every time you say “simple” I gulp Amazing work!

[@jeremiahmolinaro7595]

You are brilliant and this was kinda fun to watch. I love how you edit the video so efficiently.

[@hirohitotorres9406]

I remember few year ago...I was working with a car generator to be used by students in a bicycle project. Well at the beginning it was hard to spin the generator until we start to put a large resistor to the cable that goes to magnetize the field. The larger the resistor the easy to spin the alternator... obviously less power...but the student did Ok getting about 100 watts for few minutes....until getting exhausted,,, Good effort Samm!!!

[@nightmareinaction629]

How is this channel not famous just subbed

[@epiczone3828]

Well the recipetiers for the Alternator are below the feild winding because when it’s rewinding the Alternator needs to go through the fresh hold at only 13volts when they regulate between Engine spins because they are meticulously harder to spin with lower Voltage power

[@ShafaqIftikhar-pw9ld]

Very nice project and explanation. Thank you for the upload!!!!

[@ClarkSchaefer]

Fellow uni student here, pretty much nailed all the important bits.

[@pedroguilherme4170]

Sir, you are just a genius! Respect

[@RS-nl2lp]

Why 132 dislikes? I am a mechanical/electrical engineer, and this is a very acceptable explination, the video description i fairly precise and the guy seems OK....

[@epiczone3828]

Well the recipetiers for the Alternator are below the feild winding because when it’s rewinding the Alternator needs to go through the fresh hold at only 13volts when they regulate between Engine spins because they are meticulously harder to spin with lower Voltage power through pin13

[@p00pie]

That miniature ignition system is very cool.

[@SammSheperd]

I haven't actually been taught the 3 things, I came up with that, so if there is some fatal flaw in it let me know.

[@mikhailmorozov1132]

Hi Samm, I think there is no fatal flaw in the above mentioned except that you left out the current flow through the generator. With increased current there is more voltage drop on the internal resistance of the generator windings.

[@primodernious]

the theory behind input and output of a generator is an error that is classically taught in shool. actually you don't have an alternator, you have a motor that is reverse run as a alternator. relative motion between magnet an output winding causes motor reaction. if magnet and winding is stationary and steel slide in between magnet and coil, power is still generated even this there is no reactive force. such a system i describe is a real alternator and i have built one that worked, that had zero mechanial resistance and a noticable current on the output.

[@TerrariumFirma]

So make a video about it. Don't be shy.

[@scuffieduffie]

You didn't put the valve cover on.

[@gingertimelord5]

only thing i would have done differently is using a more common alternator with a built in regulator/rectifier circuit ... in many occasions where i have had small engine machines and needed to add such a thing (charge a battery for a winch or power lights) i have always gone to the abundant and inexpensive delco one wire type .... it has one big terminal that goes directly to the battery (hense the name) and thats all that needs to be connected .... from there it does have two small spade connectors for ammeter and warning light but those arent needed to generate power

[@Dan-nj8du]

5 minutes into a 7 minute video and you FINALLY start talking about the regulator.

[@aSpyIntheHaus]

That little engine is running sweet. You've done well and great find. I'm not sure how cold it is where you are but if you have a little desk fan handy and set it up so its blowing over the engine... I mean if its going to run for any longer than a few minutes that is, it mighn't be a bad idea.

[@SammSheperd]

Thanks! Yea I can't run it for more than a few minutes before it gets too hot and starts to burn oil. I was doing power output tests with an RC airplane motor and propeller which I was also using to cool the motor.

[@mark_osborne]

Really enjoyed your brilliant video ! Instead of having a built in regulator, or even a divorced regulator that resides under the hood, (usually bolted to the firewall), most modern car/truck alternators are controlled by the PCM. I'd really like to know if the code is as simple as yours- I'll bet it is !.... why not ? Turn on the field, when necessary, and turn it off when it's not needed. Furthermore, many cars, especially Chrysler products have battery temp sensors, so the code could be written to charge the battery according to temperature. Also, I've seen inductive sensors on the battery cables, indicating to me, the PCM is monitoring current flow to the battery. All of these points could be adjusting the voltage and using the "on/off" principle you've displayed in this video. ---Kudos !

[@blackz06]

It's very crude. PWM is the proper way, and how OEMs do it.

[@mark_osborne]

@@blackz06 You are correct, since my post in 2014, I have since learned it is PWM. Also, if you read my reply (above), everyone of the points I made turned out to be true. But I missed one. The algorithm also attempts to extend battery life !

[@blackz06]

@@mark_osborne Yeah, I was just commenting on the PWM aspect.

[@Jbk-qi5tk]

I liked it, very well put. You were a little too fast though, everything you stated quickly could've had a little more detail too is in a slower pace so everything could be completely understood.

[@derekbigpowers1993]

This is all pretty basic stuff

[@edspencer7121]

Very ingenious! like the timing advance on the ignition 👍

[@amitpatelpatel144]

I love your starting system at 6:00.

[@kevinnewell5996]

I'm doing something along these lines. I have one of those 350 watt Free Electricity wind generators that goes on a stationary bike. I picked up a cheap 12v drill for the motor that will run the generator via chain. I could simply put a voltage regulator between the generator and battery bank, but I need to figure out how to turn the motor on when the voltage in the battery bank dips and off when it gets back up to where it belongs. This would let me run a hydroponic greenhouse without grid electric.

[@Iflyagrasshopper]

Hi Sam it seems like you need some smoothing for your field circuit. what about using a capacitor ? or something like a comparitor to produce an analog output? I like the little engine though... I have some similar ones with a permanent magnet alternator built into the flywheel. they are out of a chinese inverter generator. I was trying to make an auto start circuit so the gasoline generator could be hooked to some batteries (24 volt) and use the batteries to run an inverter. The idea is to use solar and wind as the primary charging but the engine as a last resort. I'd like it to be all automatic. This way you could use power and have the system guarantee that your power is always available. This would be great for an off grid power system such as a remote cabin or camping.

[@Townsonbck]

That's so cool! I'm playing with the ardunio so I can control throttle to power up based on alternator load. Having a hard time with the code. It would be so cool if I could accomplish this. Nice video!

[@sunshine7453]

Very well explained. Thank you!

[@SvenAlmgren]

Nice that you uploaded the other video :)

[@JooJ19]

Really well explained, thanks

[@mitropoulosilias]

if you put load on the alternator there will be resistance in the alternators axle and you need more gas to keep it running. you must make a controller to keep the rpms. but this is on alternators with voltage regulator and no field winding (comon cars alternator)

[@HoustonALEE]

Hello, thank you for this marvelous video filled with amazing knowledge. I am Alee and I would like to ask you a question that you can hopefully provide feedback. I am not a electrician by some definition but by others I am for we, us , everyone creates energy of some sort so electrician as a whole are. Fast forward: Can you provide with any advice or opinion for those that have wondered how to modify a lawn weed Wacker or and lawnmower by converting the start up to a switch instead of the original pull start mechanism?

[@FSstefan7]

i love your video's!!!! all of them. keep doing wat you are doing

[@zoomie9134]

Great video Sam, I love it! keep it up!

[@larrymartin1521]

you're. the smarthest. guy I've. seen yet.

[@1-Six-dee]

Nice video man I apreciate it not as simple to understand for me as it may would be am engineer but my education is probably not up to par to some but thanks I did learn a few things

[@justabouthadit5872]

Gonna need a cooling fan if you want the motor to stay at operating temperature. I suggest getting a pulley off an air compressor, some have a fan with a pulley built around the outside.

[@yak55x]

What are you studying? Reminds me of A&P school but you seem more like an engineer ( in a good way) Nice timing adjustment :) Fun projects, thumbs up.

[@SammSheperd]

I have a B.S. in Aviation Technology. I'm a CFI and commercial AMEL. I also worked in hangers for like 3 years working on aircraft under A&P's but never persued my own A&P qualifications. I can sure change the oil and pull the plugs in a jiffy though. I was put off by engineering when I learned it was all just solid math. I didn't learn to appreciate what engineering was until 2 years into college

[@TauCu]

I love that 4 stroke.

[@scamper_van8470]

thumbs up for the project

[@scamper_van8470]

But my question is how do i make work Arduino as an AVR "Automatic Voltage Regulator" to which i connect an electric motor as driver and another electric motor as generator?. What i want to know is where can i find the code for arduino in order to make work arduino as AVR and which components i need? If you don't know please keep your urge of posting anything since it won't be of any use to me or anybody else that is loocking for similar help, avoid stupid comments THANK YOU!. Do please all of you that think to say you cannot generate electricity with an electric motor well i tell you you are ignorant and you should go back to school!most of all you should get well informed with what materials are built both electric motors and generators. Someone said: Ignorance is a Blessing for Fools and Idiots.

[@flaplaya]

You are smart but forgot many aspects here. Reluctance, Induction, Impedance, Power Factor, the list goes on.. The fact you know of an alternator as a three phase delta source supplying (3 diodes/Sometimes 6) to direct current via a voltage regulator is good enough for me.. The ignition setup, Writing code, You sir are elevated in I.Q for sure.

[@Impedancenetwork]

It is highly, highly unlikely that the alternator/generator is wound as a delta. Almost all generators are internally wired as a Y (some people call that a star). It is possible that vehicle alternators are wired as a delta but I would bet a lot of money that that alternator is wired as a Y.

[@jvsyoutube3298]

What was that ignition system you used for the motor??

[@jamest.5001]

the main reason I clicked on this video is that little motor. or engine. that little thing is cool! do you know what brand it is. and the displacement. I would like to get one. and what kind of ignition system was that? I never seen one like that before. I already knew how a alternator works. but I really like seeing cutaways. but I couldn't ever make one from something useful. I guess its just seeing all the parts at home. views from there point of view. great video.

[@emiled9550]

Cool educational vid, keep it up.

[@Chiller3k]

Hey Samm, really cool video! Just out of curiosity: Why didn't you use the PWM output of the Arduino and then a simple PI-controller (implemented on the arduino) to control the PWM output? Also, when switching a current to an inductor don't forget to use a free-wheeling diode. Otherwise you might damage your components. Especially with a Coil as big as this one.

[@SammSheperd]

An aircraft mechanic told me this is how an alternator controller works, so I guess this was my test. I'm also not very proficient with arduinos or coding. Yea I wasn't sure how a transistor would handle the spike when turning off an inductor. Thanks for the info.

[@luckychileya7248]

well explained and keep it up.

[@BuddhismHotlineTV]

Lucky Chileya unfortunately this amazing man passed away recently, Rest In Peace.

[@luckychileya7248]

my condolences,i was hoping to learn more from the good man,RIP

[@Brincandopabajo]

Good job!!

[@t3mulligan]

Hey, any advice on where to look for an old aircraft alternator?

[@FourSeasonsHD]

What do you think is the maximum useful output of an unregulated alternator to charge batteries for an hour as quickly as possible? The idea is to charge in an interval for an hour and let it rest for an hour or preferably two. And again. Thus reducing the generator run time to minimum (1:1 or even better one to two).

[@SammSheperd]

Alternators have a maximum current rating

[@FourSeasonsHD]

There may be considerable safety margin for continuous output. Ideally all amps would be taken out without melting anything during the charge interval. The shorter the charge interval, the more rest for the alternator. I guess it has to be tested in a lab.

[@robmad7657]

Hi Sam, Interesting project. How much watts did you able to reach with that engine?

[@Hopeless_and_Forlorn]

Nice job. I assume you put a free-wheeling diode across pin 13. I must say I have seen some crude ignition advance mechanisms, but yours takes the cake. But of course it works.

[@blackz06]

Why a diode across pin 13? Nevermind... just remembered the field is a coil lol

[@auladepiano]

Excelent Excelent video. Thanks for sharing

[@ATOMICBROADCASTS]

where'd you get the ignition system? very neat

[@alexzitnik6606]

Hey. I'm looking to make a vertical wind turbine as a school project. I need the turbine to generate enough power to charge a car/hobby battery. I'm a little confused on how I use the alternator. I need help with fully understanding on how to wire up an alternator so it can charge a battery. If it's possible, can you make a video

[@edarcturus1065]

I like the throttle control, the way you move the hall sensor's position.. huehuehue. By the way what transistor you are using? 2NXXX???.... or IRFXXX???...

[@davestech6357]

There's six diodes in the alternator not three. What's the model of the outrunner motor you show? Looks like it could really move some weight around.

[@SammSheperd]

2:50 "There are six big diodes that are used to...." It's an Emax 5335 - 08

[@joseppi2610]

hey what size of brushless motor are you using

[@SammSheperd]

Lol, um.. that's an EMAX GT5335 -08 250kv

[@joseppi2610]

wow thats big I usually use a gt 2215

[@SammSheperd]

Yea I haven't used it on anything it's from some crazy idea I had and didn't finish

[@joseppi2610]

yea i also have some big motors like that that i haven't used

[@heronimousbrapson863]

Shouldn't there be SIX diodes for full wave rectification?

[@simeonmoore9620]

Greetings Samm. I've got a question. What transistor did you use for the voltage regulator circuit? Thanks

[@gsmmantu3971]

nice video sir

[@1marcelfilms]

That weedwhacker motor runs way too nice at such low rpm

[@michaelhefner4813]

So when I plug in my batteries my brushless motors are very hard to spin is it because what you should on the brushless motor or is it the voltage of the battery my Leipold battery is a 11.1 V battery thx if you could help that would be great

[@SammSheperd]

+Michael Hefner well the brake function on some esc's just connects the wires together to slow it down. You think there is a problem? I'm not sure I understand what it is.

[@mohammadjulhas6417]

Very.good.job

[@stuartowens3506]

Fun video!

[@michaelhefner4813]

Good videos

[@pR1mal.]

Rest in Peace, Sam.

[@hungrynapps]

do a car alternator push d same current example 100amps at high rpm n low rpm? ..

[@SammSheperd]

Instead of the perspective of "pushing amps" lets say that the system tries to draw that load of current. Alternators are able to provide more current at higher RPM, because there is a lot of voltage sag in the alternator and the system when under high current draw. So when high current is drawn, the voltage that the system sees drops and then the alternator can produce a higher voltage so that the system then continues to see the correct voltage.

[@SomeGuyInSandy]

Well done! =)

[@thra5herxb12s]

Car alternators generally have a voltage regulator built into them.

[@mikeman400]

Is it possible to regulate up to 48-50v for charging a 48v battery bank?

[@tobiaswittenmeier1877]

Its always possible to use a step up DC/DC converter to inchrase the voltage.

[@duettatraktor7949]

mikeman400 yes you will have to spinn the generator verry fast tought.

[@duettatraktor7949]

mikeman400 im getting 330v from a car alternator thath i have to gear up to about 10k to 20k rpm.

[@duettatraktor7949]

mikeman400 you need to make your own voltage regulator the one in the vid i dont think will handle 48v

[@dhyeybhandari2305]

Duett A Traktor it is possible to get 220v AC by car alternator???

[@georgebrooks5307]

Ever thing of making one of these set up with an electric motor add 4 deep cell batteries I think it would be one hell of a generator

[@Reddylion]

thanks

[@jamest.5001]

where do yo get all the alternators from? I need one can you tell me where to get one used?

[@SammSheperd]

I walked to the shop at the airport and was like "do you have any un-airworthy alternators I can use for a project?"

[@conroy2757]

Whats the name of that motor

[@kevindeschamp-cdot7820]

How does a electro motive train work? Electrically and mechanical.

[@SammSheperd]

I'm no expert in that, but I'm pretty sure they use a huge engine as a generator and an electric motor for propulsion. This is because of the ridiculous amount of torque that trains need. Electric motors can provide crazy torque at 0 RPM. Essentially using the electric generator/motor as a transmission that needs no clutch and stuff.

[@jeffflanagan2814]

Can you tell me where to find that ignition system?

[@mitropoulosilias]

hobbyking or other rc shops

[@MPrentice]

Ok I will see you next vid

[@MPrentice]

when's your next video coming out?

[@SammSheperd]

I am unable to schedule my videos. Currently it's dependent on the weather

[@adalarasan193]

I need complete wiring demo of car

[@JCHANDYMAN1970]

Dude is smart!

[@mikhailmorozov1132]

Also why do have 1.4=14.2 commented out in the code? Your voltage divider gives a ratio of 0.09, with 1.5V sensor voltage that should be 16,6 Volts output voltage. The output voltage seen in the video seems to be much lower than 16.6. Perhaps you should make some more hysteresis between the on and off voltages to keep the switch from switching madly between on and off with a correspondingly low duty cycle. For example 1.4 is off, 1.3 is on to get a nice 15V charging voltage.

[@SammSheperd]

+Mikhail Morozov honestly is been a long time since I figured it out. I should document things better.

[@MrDylman55]

I didn't now about the energy with the 3 connectors on your motor

[@SammSheperd]

It only has 3 wires because it's wound in a 3 phase configuration. The alternator is also wound in 3 phase. But a single phase configuration (2 wires sticking out) is also perfectly fine.

[@MrDylman55]

Samm Sheperd, sorry but I think that it was midnight when I commented so I didn't understand anything. sorry to waste your time.

[@SammSheperd]

thanks No worries man :) I was just browsing through older comments. Glad you found it insightful

[@chrisbow99]

Were can i get one of those electronic ignition systems.

[@SammSheperd]

www.ch-ignitions.com/

[@mitropoulosilias]

hobbyking, check for cdi for single piston gas rc plane.

[@TheBirells]

oww dude... so cool!

[@AVagrant_]

so is this why you wanted to get into the machine shop the other day? lol

[@SammSheperd]

No I did all this in the fall lol. This thing sat in my shed all winter, I filmed all this a month ago. I'm slow.. haha

[@AVagrant_]

lol! i recognized the engine, I think I remember you showing me, or at least telling me about it, glad you figured out how to control the spark

[@paucliment9280]

too much info for my brain JK. But you made like a bec?? Love your videos

[@bulantuy]

why did you connect it to pin 13 when you want it be PWM?????

[@SammSheperd]

+Andrew Maraguinot it's not true pwm

[@bulantuy]

pin11,10,9,6,5,3 are the pwm pins??

[@edarcturus1065]

The field's PWM is triggered by the rise/drop of the output alternator voltage and not the arduino's internal clock.

[@ЮрийДолотказин-с4ы]

Arduino in application like this looks like overkill. :)

[@MrGarcon98]

i had learned that diodes make elec go one way only ,,they dont change ac to dc ! an inverter does that ,,,,whats up !

[@SammSheperd]

Diodes are used to turn AC into DC. Inverters are used to turn DC into AC

[@MrGarcon98]

diodes are a one way switch kinda ,,,your wrong INVERTERS CHANGE AC/TO DC OR REVERSED

[@naturalmilkhoneyandzenretr9508]

Make me one please

[@powerthoughtsontools4831]

Samm Sheperd, crud! - Wish i knew the things you knew in regard to electronics, And in my case my desire to use a homemade bike pedal sprocket drive system. Wouldn't that be a self-reliant project to drive a small generator to juice my weak battery during the dubious times the car will not start in the middle of nowhere. mrflarkusAtgeemail

[@kwhp1507]

Man I miss samm’s videos. What a loss to society...........

[@JaimePorras87]

God man this Doode would have been the next Tesla... His intelligence is ridiculous, "creating a Square Wave Pulse Width or something"

[@keepinitsk8a516]

usually I watch videos sped up by 1.5 or 2 but you're talking too fast for me lmao never thought I'd say that. i tried slowing it down by .5 but then that was too slow...

[@keepinitsk8a516]

I think this is only because i don't know what you're talking about so my comprehension is slow and you're talking at a cool speed had I been able to comprehend better, so i just play things over a couple times when you lose me.

[@MPrentice]

And your supper smart

[@Cotronixco]

His breakfast ain't so dumb either.

[@SammSheperd]

How do you know what I eat for breakfast? lol

[@hortensemarle3195]

France

[@benlawton5420]

I though alternators had a voltage regulator built in.

[@SammSheperd]

Some do

[@benlawton5420]

*****​ Thanks I'm going to build a hydro and wasn't sure what to use.

[@MPrentice]

hi

[@SammSheperd]

sup

[@michaelhefner4813]

Please help

[@Impedancenetwork]

Voltage doesn't flow. Current flows. Always makes me wonder how much someone actually knows when they make such fundamental mistakes by saying, "voltage flows..." If that slipped out of my mouth I would instantly correct myself.

[@SammSheperd]

Voltage causes current to flow. It was a poor choice of wording

[@sickofliberals9403]

Ok got it, why won't my truck run?