Research and Development of Concept Leading to an Automotive Alternator with Significantly Improved Efficiency and Weight. Final Report, February 1, 1979-January 31, 1980

摘要

The goal in Phase 1 of the subject project was to achieve a 20 to 25% improvement in both output/pound and efficiency relative to control performance of a present-production Delco No. 1102848 alternator. This was to be achieved by substitution of redesign stator of equal or smaller weight and size and in a configuration leading to low cost and manufacturability. Analysis of bench tests on the subject alternator incorporating the redesigned stator reveals an output/pound improvement of 30% thereby exceeding the design goal, and an average efficiency improvement of 25% easily equalling, and at most points of the performance curve, exceeding the design goal. This was achieved in a design employing proven, low-cost, high volume manufacturing techniques. The redesigned stator also lends itself to direct interchangeability with stators in production alternators. Major improvements in the rotor remain to be made in weight, iron losses, and field copper losses. These needs will be addressed in Phase 2 of the subject project. For purposes of baseline comparison the same alternator parts will be employed insofar as possible as in Phase 1. Stator iron and winding refinements, heat runs, study of reactances, and practical tests should also be addressed as ancilary projects following Phase 2. (ERA citation 05:016114)