Quote:
Originally Posted by Jonny H
^ Smells fishy. There is absolutely NO WAY that an alternator based on the standard case can sustain an output of more than around 90A for a prolonged period. I am not disputing that the output can peak at 160A, just that it cannot sustain that output in the real world. How do I know? Well...
We have improved the windings in the standard case to increase power output. Once you get above 90A continuous current, the heat generated by the alternator cannot be cooled by the flow of air through it, especially if the engine fan speed is low. The main reason is that the standard alternator case has no internal fan and secondly, the alternator is encased by the engine fan, blocking air flow.
Anything above 90A continuous, the alternator will get so hot it will melt the insulation on the windings and short them out. Several alternators were harmed in these experiments.
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Yes, it's as simple as that. Totally agree!
1. The number of winding turns and wire size used in the stator determines max output.
That then determines the required physical size of the alt.
2. The diode rating (amps) and the size of the diode mounting plates determine the max current output.
3. The rotor windings (rotor current) also affects the max output.
The above constrains the overall physical size of any alternator design.