VEHICLE ENGINE POWER

SAFIERY UNIVERSITY
REPLENISHMENT POWER
FROM ENGINE ALTERNATOR
BACKUP FOR SOLAR ON POOR DAY

This article is designed to give primary power and/or solar back-up power choices available to the reader from engine power using either the vehicle supplied alternator or adding a second high power alternator.

MAN 6x6 with 8kW generator driven from PTO

PRIMARY POWER WHEN TOURING

After camping overnight and driving till midday to next campsite, the on-engine alternator will be a primary source of power. The energy delivered is measured in a 3 hour drive with and without solar production.

BACKUP POWER WHEN CAMPING

After finding the perfect campsite, the on-engine alternator will be a backup source of power. In poor weather, or if touring southern Victoria or tasmania, back-up power is essential. The energy delivered is measured at an idle of 600 rpm for 1 hour with and without solar production.

It is far more convenient and economical to run the alternator for 1 hour than a Honda EU20 (2kW) for 2-3 hours to produce a similar result.

Solar Backup Power
  Using Honda 2000W Generator Using Safiery 5kW Alternator
Fuel Petrol Diesel (Engine fuel)
Weight 35kgs plus Petrol 20kgs 10kgs
Convenience Smell and safety of carrying petrol Turn the key
Power to batteries when running Assumng battery charger is 1.5kVA then Honda should produce that power but not on eco-thottle. At idlle, 2.5kW direct to batteries
Hours to Replenish 800Ah (12V equivalent) of Lithium (assuming air-conditioner run off battery while in camp.) 6.5 hours 3.8 hours
Hours Driving to replenish the same amount. With 840W DC to DC from Alternator then > 12 hours Less then 2 hours

 

Alternator Power Source Choices

Power Size
(all 48V DC)

840W

1300W

5000W

9000W
(Shown in photo above)

Method

Using DC to DC from existing Alternator

Using DC to DC from existing Alternator

Separate 48Vdc Alternator plus smart DC Controller:

Charging Control System for Recreational, Special Vehicles and Boats using Lithium Battery SOC

 

Australian Patent  2020100438

Separate 48Vdc Alternator plus smart controller with power output at charging profile

 

Alternator must be able to deliver 35A @ 24V

Alternator must be able to deliver 70A @ 24V

Alternator is 5kW

Alternator is 9kW

Dependency

Power curve of existing alternator

Power curve of existing alternator

Power curve of alternator shown

 

Power output at 1200 rpm

840W

1300W

5000W

5200W+

Touring:

Power delivered typically in 3 hours driving

Typical Daily use no air-con is 2000-3500wh

1800Wh

3500Wh

>12000Wh

> 12000Wh

Backup Power:

Poor Solar Weather vehicle engine running at idle (600RPM) for 1 hour

Typical Daily use no air-con is 2000-3500wh

300Wh

800Wh

2500Wh

3500Wh

Price

Excludes GST

Subject to Change

$661

$1,890

$4,000

$18,300

Inclusions

 

 

Includes Bracket, dampener and belt

Includes Bracket, dampener and belt

Application

4WD/Motorhome
Mercedes Sprinter
(may have 2)

12V 

4WD/Motorhome
12V or 24V

Mercedes Sprinter
Motorhome

12V Vehicle Power

Expedition vehicle
12V or 24V
Vehicle power

 

5kW Alternator and 5kW DC Power Controller

Here is the Alternator performance for the 5kW option in Column 3.

These alternators have a NON-LINEAR power curve as significant power is needed at idle.

Typically a 3.0 to 1 ratio pulley diameters is chosen. This increases the Alternator speed by this same ratio to engine speed. At 600RPM idle, the Alternator will be spinning at 1,800 RPM. This puts it in the range of significant idling power of 2.5kW.

At cruising speed, the engine may be around 1200 RPM with the alternator at 3600RPM. It will produce 5kW at this speed.

The alternator output is controlled by a CANbus interface DC Controller.

Lithium batteries have revolutionised energy storage. Stored lithium energy can run air-conditioners, cooking appliances, high power communication systems and other power hungry devices. Large lithium systems are now compact enough for mobile applications.

The difficulty, until now, is replenishing the lithium battery energy. Solar and the vehicle's alternator are "self contained" options. However, a 2 kW Solar panel array on a mobile installation is massive in area. It also only replenishes for limited hours, has variable power, and is only effective on a good solar day. 

The enabling game changer is rooted in a simple application of high power alternators. It is not renewable energy but very close. It "steals" in-efficient power from the engine to generate DC power while the engine is running. It can produce up to 9kW of power. This power transfers directly and efficiently to large lithium battery sets. Within hours of driving or even idling, you can store energy in Lithium batteries. Whilst this technology needs the vehicle engine to run, it doesn't have to run for long.

An 8kW portable genset may weigh 160kgs+ and measure 800 x 800x 700mm. It will need an additional battery charger to transfer energy to stored lithium batteries. The 3kw Alternator weights 9kgs and the 9kW DC weighs 15kgs. The size is compact: 245 x 220 x 220mm, runs at 48VDC and transfers power directly to the lithium batteries. Game Changer!

9kW Alternator and 9kW DC to DC Converter

Photos of the power in and out of the expedition vehicle:

Photo on left shows 12kW power going in from the 9kw Alternator plus solar

Photo on right shows 14.4kW power going out through 3 x Induction Cooktops and 2 x Miele Ovens.

48VDC becomes the baseline for stored energy. This is the same baseline used in home energy storage systems. It provides an efficient energy system and is less than the voltage level requiring a step up in electrical safety. This keeps it affordable. The 48V DC generator combined with lithium batteries is not only a true hybrid power system, but an incredibly efficient one. It will become the norm in off-road applications.

 

 


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