Alternator Rewind

Gauge 22 is not especially delicate, and should be easily solderable if needed. If the amperage of each winding is within the ampacity of 22-gauge wire, you ought to be okay.

Could you provide the following information.

Target rpm required for new alternator.

Target out put both volts and amps.

Thanks

Have you ever tried to rewind a motor or alternator?

I'd suggest making your own alternator like the one shown here...

http://www.otherpower.com/turbineplans.shtml

Scan the whole site for sound practical advice on small wind power. Making everything work with a grid tie inverter (with or without batteries) will be a challenge. Is this project designed to reduce utility costs or is it just for "enjoyment and education"? Good luck either way!

Why use a grid tie wind turbine if the intent is to be off grid? Conversely if you truly are going to be grid tied then an automotive alternator is a poor choice as your generator. Much effort and possibly expense for little return.

To generate the kind of voltage required to match grid tie conditions you need somethng like a PM generator because its easier to wind your own coils to the requisite number of turns use the correct size wire gauge for the required amperage.

For general conversions of amps and volts the following generally applies.

decrease wire cross sectional area by half = a decrease of amps by half.[working current]

Increase No of turns by 2= increase of volts by 2 [assuming speed is the same]

Decrease speed by half = decrease of volts by half

The results can be interpolated from the original ratings

The working Amps of 22AWG in windings would be about 5 Amps so if this is your comfort zone you can calculate all other values to suit.

It is also recommended to change the rotor windings to suite a higher voltage this can help to reduce the rotor speed but power input has to be maintained so it will result in different geometrys for your blades.

There are readily available alternators available in 12, 24, 36 and 48 volt configurations. If you start closer to the target voltage, and rework the regulator to gain the rest, it should be easier than building your own alternator, or trying to rewind one. Good luck.

if you are trying to get ac you will need a constant speed drive

Automotive alternators are rated at somewhere around 700 watts, at best, so don't expect to get more than that in the envelope of one. Larger alternators have larger frames.

Why not use a transformer to raise the voltage to a usable level? It's simpler than rewinding an alternator . . .

A lot of appliances will operate at 50 to 60 Hz, so speed regulation is not as stringent as one might imagine, but nevertheless, some sort of speed regulation is needed.

An alternative plan may be to search the local 'flea market' papers for a "generator that needs work," for $50 - $100. The "needs work" problem usually mean that the gasoline engine doesn't run. Take the alternator off and use it.

Do you have a scheme for regulating speed?

GA from me.

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To the OP, how are you going to control output and frequency to allow connecting to the mains??? That is not a simple task.

Nor is it without dangers.

Also you need to be licensed to do it.

The equipment has to be certified as well......

Even making mains AC at home from a wind turbine is usually best done with 12 to 48 volt DC batteries and an Inverter.......especially if you do not have much of a clue.......

One option you may consider is to not rewind the alternator, but remove the rectifiers and voltage regulator and use three appropriately (meaning: having the current capacity needed) sized transformers to step up the voltage---then rectify and regulate off the secondaries. The alternator is 3-phase, hence the need for three. A 120 to 12 volt transformer used in reverse will work well. Don't worry about the frequency issue, because an increase in frequency will increase the efficiency. The cutoff frequency of a 60Hz transformer is most likely well in range. You may not have to increase the RPM's as dramatically as you indicated. A little experimentation will tell.

If you want to wind a custom transformer there are plenty of sources on the web to guide you on that. Winding transformers is certainly easier than redoing an alternator!

Good luck.