Generator/Alternator Redesign to Optimize Electrical Power and Improve Reliability

NCMS Project #: 142197

Problem: Ever increasing environmental and operating challenges tax batteries and alternators to their limits.  Today’s vehicle fleets need properly specified and designed alternators to ensure they are not under powered in capacity, run efficiently without overheating, and are more reliable for longterm and optimal maintenance and sustainment.

Benefit: The completion of the project will serve as an example to commercial industry in providing better, safer, and more cost-effective technologies and processes to redesign vehicle alternators.

Solution/Approach: The solution is to advance the state of new technologies and engineering processes to redesign, integrate, and test a more advanced and reliable alternator/generator to meet vehicle power requirements and reduce electrical system maintenance costs.  This initiative will pilot a new approach to develop innovative solutions of a 180-amp alternator that includes better technologies and materials in the windings to reduce internal resistance within the alternator to minimize maintenance downtime and maximize operating efficiencies.  The goal is a redesigned vehicle alternator that meets the vehicle electronics requirements, but is lighter weight, performs better, lasts longer, and is more cost effective than the current solution.

Impact on Warfighter:

  • Enhance vehicle operational performance/availability 
  • Increase warfighter safety and readiness 
  • Decrease lifecycle and maintenance costs 

DOD Participation:

  • Tank Automotive Command Integrated Logistics Support Center 
  • Ground Vehicle Systems Center 
  • Project Manager Self Propelled Howitzer 
  • Army Test and Evaluation Command 

Industry Participation:

  • Defense Engineering Services, LLC
  • NCMS

Benefit Area(s):

  • Cost savings
  • Positive environmental impact
  • Maintenance management improvement
  • Energy efficiency
  • Durability
  • Reliability improvement
  • Lightweighting

Focus Area:

  • Reliability improvement (hardware)