Here is another old message on the subject I just found.
I think either Mark Suspinski or Mark Steitle thought of
using the Harley. Also Mistral mentioned flywheel starter
generators before that.

I tried to send this message 3 times today but the stupid people from
the #.#.# cannot figure it out. So far they have refused
to forward it. Just because you are being paid over $100,000
does not mean you have any knowledge. They passed it through
back in 2006 but a different and probably smarter party was
in office then :)

Paul Lamar



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-------- Original Message --------
Subject: Flywheel alternator
Date: Wed, 25 Jan 2006 07:23:47 -0800
From: Rotary Engine <rotaryeng@earthlink.net
To: AA-me <rotaryeng@earthlink.net


Even if the revmaster alternator (dynamo) won't work as it sits,this
design seems very easy to copy.  The RPM issue is not a real concern since
the magnets are the only part of the assembly that's exposed to high rpm
load.  If one were really concerned about reliability, an alternator like
this could be constructed at each end of the engine, or two nested on one
end, probably even driving by a singleset of magnets..  I suspect that the
alternator magnetic pickups are divided into two sets just like the CDI
energy coils.  I know that GAMI was working on an engine electrical system
that electronically combined the output of two alternators to provide
redundancy(*); there's no reason that RevMaster couldn't have copied that
concept.  Whoever talks to RevMaster about this beast please ask about that.


     Russell Kent

     (*) On the theory that solid state circuits are orders of
magnitude more  reliable than mechanical drive line parts.



     Just talked to Joe and he said the coils are in two groups of five.
Two separate alternators with rectifiers.  30 amps total.  He feels it might
go to 7000 RPM but he will sell just the magnets and stator coils and we can
do our own carbon reinforced flywheel.  He has the magnets cast for that
radius.  He also says the neodymium magnets saturate at 4500 to 5000 RPM but
there is no real problem running it higher.  You can reduce the saturation
by moving the coils radially inward if necessary.  "Neodymium magnets offer
the best value when comparing performance, size and cost.  They are moderate
in price, very strong magnetically, and typically allow for dimensional
reductions.  They have poor resistance to corrosion and should have a
coating or plating applied.  Consideration should be given to the grade of
alloy when exposing Neodymium magnets to temperatures above ambient room.
Neodymium Iron Boron has good resistance to external demagnetization fields
because of its high Intrinsic Coercive Force (Hci) .  This resistance makes
Neodymium magnets an excellent choice for electromechanical applications."



     Paul Lamar ...No rotor no motor.

Great information.  This is a good direction to be going with electrical
power.  Joe sounds like a pretty generous sort.  Paul, is your interest in
adding strength to the flywheel driven by concerns about the added mass of
the magnets?  How heavily loaded is the flywheel without the magnets?
Regards,

Matt-

Yes.  The magnets add mass without adding strength.  I think
we need to take a close look at 7500 RPM.


Paul Lamar

Something else to check for is a galvanic reaction between carbon and
the flywheel.
Carbon will definitely eat Aluminum.  I assume to lesser degree steel.
Some people use an insulating layer of epoxy/glass between the carbon
and AL.

Cheers
Cary

Paul,
Have you looked at the after market high-output units for Harleys, sold
by Compu-fire (http://www.compufire.com/pages/harley-main.html).  They
claim 40 amps, 25 amps at idle.  The unit has 18 coils.  Looks like it
could possibly fit between the vibration damper and the psru plate.  The
entire kit sells for $400.

Mark S.


"3Phase Charging System The Compu-Fire 40 AMP 3 Phase charging systems
provide 25 AMPS at idle and 40 AMPS continuously above 2800 RPM.  The unique
narrow rotor and stator combination fits Softail/Dyna primary cases and the
voltage regulator bolts on without any frame modifications.  The precision
balanced vented rotor keeps the stator cooler in closed primary systems to
maintain maximum output under all high current draw conditions.  The large
flanged seal spacer provides maximum support for the rotor and the voltage
regulator output is calibrated to 14.25 volts from idle on up."


Wow that is a bargain. More current than Revmaster and way less cost.
It could also fit around the PSRU snout possibly. Then you don't have
to worry about it blowing up at 7500 RPM.

If it will live on a Harley it will live on anything :)

I'll think I will go out there and take a look.
I'll also send them email and see if they can give me the dimensions.

Paul Lamar

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