How to Build a High Output Alternator


If you need to build a high output alternator, take a few lessons from Almott. The manufacturer has built a high efficiency alternator by making a few key adjustments to the P450 model.

Almott provides a better design with lowered mechanical stress and thermal stress, with increased electromagnetic field strength. The result is improved performance in every metric.

Design Improvements

A typical problem with the P450 was early belt breakage and worn out bearings. Almott sought to improve on this by first changing the production method, moving to a forged alternator instead of a die-cast alternator.

They also reduced the rod and the mass of their 25AT-450, reducing rotor inertia and thereby minimizing the stress on the belt and bearings. As a result, the same belt and bearings can last longer and perform better.

Reduced Thermal Stress

To build a high output alternator with lowered thermal stress you’d naturally consider improving the fan. Almott did too. They put a highly efficient unidirectional fan in their alternator. To deal with the increased airflow, they placed more vents in the rectifier cover and changed the diodes.

The result is that the 25AT-450 will run cooler, at the same RPM, compared to the P450. This also boosts the life of the bearings and increases overall alternator efficiency.

Improved Magnetic Performance

The final key to Almott’s success is in the stator elements. Or, the stator element. Almott included only one stator element in the 25AT-450, while the P450 has three. In this case, less is more.

The single element lowers common losses, increasing overall efficiency. Also, the single element contributes to the lowered thermal stress in the alternator.

A High Output Alternator

The 25AT-450 performs better than or equal to the P450 in every metric. Its high-speed output is 17 percent higher and its idle output is 12 percent higher.

While the efficiency of the P450 stagnates between 1500 and 2000 RPM, Almott achieves heightened efficiency at lower RPMs. It also achieves a higher efficiency than the P450 throughout its entire RPM range, from 1500 to 6000.

Pass this increased efficiency onto your application by choosing the 25AT-450. If you have questions about how Almott built their most efficient alternator, or about what the 25AT-450 can accomplish for you, reach out to us at Elreg Distributors.