RACING ALTERNATORS

Lazmonsta_Typeface_-_black-green-red_30

 

Given the light weight and compact design of modern engines, we estimated that the generator would have to be no more than 100mm (4 inches) in diameter, 20 mm in length, and produce approximately 700 watts (W) per kilogram (almost 1 hp per pound) of generator weight.

Stator Core. A three-phase, nine-pole, six-magnet design with a double lap-wound stator and permanent magnet rotor was selected. Operating generator speed would be directly proportional to engine speed, with a range of 4,000 to 17,000 rpm.
An initial concern, particularly given the high generator speed, was the effect of iron losses in the stator core, which is typically an AC generators heaviest component.
Conventional grain-oriented silicon steel was not efficient enough to be used in a generator that would meet our project’s generator size and weight targets, and an iron-cobalt alloy (49Fe-49Co-2V) was used to produce the generators stator core laminations.

This yielded a 30% increase in flux density. The iron-cobalt alloy’s iron losses were further reduced via a combination of technologies. A post-rolling heat treatment reduced core hysteresis losses, and an ultra-thin oxidized insulation coating was developed, which allowed us to reduce stator core lamination thickness to one and a half tenths of a millimetre per lamination while preserving the desired iron-to-insulation ratio. These refinements reduced the alloy’s iron losses by a further 60%.

The maximum current frequency for a 17,000 rpm nine-pole generator, (assuming an equal number of poles in both rotor and stator), is 580Hz, this causes extremely fast transients, creating voltage stresses within the winding. Not surprisingly, the stator winding was wound with scratch-resistant inverter duty wire to reduce the possibility of pinholes created during the manufacturing and/or winding process, and therefore reduce the possibility of winding failure.

Rotor Design. We used a high-coercivity magnet with an intrinsic coercivity of at least 1.1 Ma/m at 160ºC, to minimize temperature increases and resultant eddy current losses, six magnets were used in the rotor’s interior configuration. Rotor diameter was reduced further to 45mm, by employing the rotor’s shaft as part of the rotor flux circuits.

A high tensile steel band encloses the rotor, preventing magnet burst at the centrifugal forces produced at the rotor’s 18,000 rpm redline. The rotor’s tapered mounting assists heat conduction and close tolerances help with utilising flux conduction from the shaft hence reducing losses. The final generator design (although being continuously improved) is cooled by engine oil, with stator cooling passages around the circumference of the hard anodised cup.

The windings and core worked out at 80mm in diameter, and the rotor 19mm long, exceeding our initial design. We have a few refinements planned, regarding higher output for ever increasing electrical requirements and two way regulator, which should be available in early 2024.

 

360-1639-generator      360-1640-generator

Relative magnetic flux densities of 49Fe-49Co-2V iron-cobalt alloy, as compared to more common silicon steel.
The magnetic flux density of our iron- cobalt alloy was increased through multiple refinements.

 


Display per page
Sort by
1 - 36 of 56 results

KTM 790/890 21+ Racing Alternator Kit

from 1,299.00 *
In stock
Delivery period: 10 working days

New MV Agusta F3 Brutale Rivale 675 - 800 Racing Alternator Kit

from 1,149.00 *
In stock
Delivery period: 10 working days

02+ ZXR400 Race Alternator / Genartor Kit

from 969.00 *
In stock
Delivery period: 10 working days

08+ ER6/Ninja650 Race Alternator / Generator Kit

from 1,109.00 *
In stock
Delivery period: 10 working days

Buell 1125R Race Alternator Kit

from 1,069.00 *
In stock
Delivery period: 10 working days

RVF/VFR400 Race Alternator / Generator Kit

from 969.00 *
In stock
Delivery period: 10 working days

SFV650 GLADIUS 2009+ Race Alternator / Generator Kit

from 999.00 *
In stock
Delivery period: 10 working days

Yamaha MT07 FZ07 2014+ Race Alternator Kit

from 1,179.00 *
In stock
Delivery period: 10 working days

RC30 Race Alternator / Generator Kit

from 1,079.00 *
In stock
Delivery period: 10 working days

RSV4 1000/1100 Racing Alternator Kit 2009-2020

from 1,079.00 *
In stock
Delivery period: 2 working days

05-08 GSXR1000 K5-K8 Race Alternator Kit

from 1,089.00 *
In stock
Delivery period: 10 working days

13+ Triumph 675 Race Alternator Kit

from 1,129.00 *
In stock
Delivery period: 7 working days

01-03 GSXR600/750 K1-K3 Race Alternator / Generator Kit

from 1,089.00 *
In stock
Delivery period: 10 working days

CBR100RR 2020+ Race Alternator / Generator Kit

from 1,449.00 *
In stock
Delivery period: 10 working days

03-06 CBR600 Race Alternator / Generator Kit

from 1,079.00 *
In stock
Delivery period: 10 working days

07+ ZX6R Race Alternator / Genartor Kit

from 1,089.00 *
In stock
Delivery period: 10 working days

11-15 ZX10R Race Alternator Kit

from 1,249.00 *
In stock
Delivery period: 10 working days

98-02 Yamaha FZR400 Race Alternator / Generator Kit

from 969.00 *
In stock
Delivery period: 10 working days

17+ Triumph 765 R RS S

from 1,129.00 *
In stock
Delivery period: 7 working days

S1000RR 09-19 Racing Alternator Kit

from 1,109.00 *
In stock
Delivery period: 10 working days

SV650 Injection Race Alternator / Generator Kit

from 1,059.00 *
In stock
Delivery period: 10 working days

-12 Triumph 675 Race Alternator Kit

from 1,099.00 *
In stock
Delivery period: 10 working days

09-14 Yamaha R1 Race Alternator Kit

from 1,089.00 *
In stock
Delivery period: 10 working days

07+ CBR600 Racing Alternator Kit

from 1,079.00 *
In stock
Delivery period: 10 working days

09-16 GSXR1000 K9+ Race Alternator Kit

from 1,279.00 *
In stock
Delivery period: 10 working days

04-05 GSXR600_750 K4-K5 Race Alternator / Generator Kit

from 1,089.00 *
In stock
Delivery period: 10 working days

SV650 Carburator Race Alternator / Generator Kit

from 1,059.00 *
In stock
Delivery period: 10 working days

S1000RR 2020+ Racing Alternator Kit

from 1,439.00 *
In stock
Delivery period: 10 working days

16+ ZX10R Race Alternator Kit

from 1,249.00 *
In stock
Delivery period: 10 working days

LAZMONSTA RACING LIFEPO4 CCP 5000-10000 BATTERY

from 199.00 *
In stock
Delivery period: 2 working days

03-05 Yamaha R6 Race Alternator / Generator Kit

from 1,129.00 *
In stock
Delivery period: 10 working days

15+ Yamaha R1 Race Alternator Kit

from 1,409.00 *
In stock
Delivery period: 10 working days

06+ GSXR600/750 ab K6 Race Alternator Kit

from 1,279.00 *
In stock
Delivery period: 10 working days

Extractor original flywheel BMW S1000RR

49.90 *
In stock
Delivery period: 2 working days

Spare part: Regulator for Racing Alternator

from 299.00 *
In stock
Delivery period: 10 working days

06-20 Yamaha R6 Race Alternator / Generator Kit

from 1,279.00 *
In stock
Delivery period: 2 working days
*
Price incl. VAT, plus delivery
1 - 36 of 56 results