› ... › Alternators.pdf · MILSPEC AlternatorsVehicle alternators were first used by the...

MILSPEC Alternators

Starting out with just one client, our first product was our 100A alternator. From there we have worked hard to become the premier designer and manufacturer of brushless alternators and portable power systems for defence forces across the world, offering an extensive range of alternators from 120 - 900 amps. With over 15,000 Milspec alternators in the Australian Defence Force alone, this is a testament to our ability to consistently delivery quality, on-time products, with a commitment to continuous development.

History & Quality

THA

LES Bushm

aster

NAVISTA

R Husky

Contents

Permanent Magnet Alternators............................................................................................4 450A Water Cooled Alternator.................................................................................................. 6 900A Water Cooled Alternator................................................................................................ 10

Inductor Alternators.............................................................................................................14 120A Air Cooled Alternator...................................................................................... .................16 300A Air Cooled Alternator Case Study.................................................................................17 300A Air Cooled Alternator...................................................................................................... 19 360A Air Cooled Alternator..................................................................................................... 20 360A Water Cooled Alternator................................................................................................ 21

Portable Power................................................................................................................... 22

BAE M

113

4

Permanent Magnet AlternatorsVehicle alternators were first used by the military from WWII to power radio equipment on specialist vehicles. Post-war, other vehicles with high electrical demands, such as ambulances and radio taxis, could also be fitted with optional alternators. These alternators used brushed inductor alternator technology.

Post WWII brushless alternators were developed delivering improved reliability and longer life. Both brushed and brushless inductor alternator technology require vehicle revs to create output, typically producing 60 to 100 amps at vehicle idle. As the vehicle rev range increases so does the alternator output. Most military vehicles continue to use this technology and most defence forces struggle with the availability of amps at vehicle idle.

Milspec has developed a range of permanent magnet alternators that solves the power requirements at vehicle idle. Permanent magnet alternators deliver instant power availability. Milspec’s permanent magnet alternators deliver 400-800Amps at idle. As a result, all battle systems can then be active at idle.

• 90% of Amps at vehicle idle: 400Amps-800Amps.• 85% efficiency (world leading efficiency levels.)• IP67: water ingress protection to 1 metre.

Compliant to:

• Mil STD 461: electro-magnetic defence capability standard.• Mil STD 810: environmental military standard.• Mil STD 1275: voltage capability standard for military vehicles.

If you require 400-900 amps at vehicle idle Milspec has the solution!

5

Specifications Units Alternators

Model 450A Water Cooled 900A Water Cooled

Type Brushless Brushless

Cut in Speed (rpm) RPM 1800 1800

Max Output Amps 450 900

Max Continuous Output Amps 450 900

Weight KG 40 80

Voltage Regulation Volts 28.3 28.8

Ambient Operating Temp Celsius -40°C to +105°C

Maximum Rotor Speed RPM 10000 10000

Mounting Specific Custom Custom#1 Coolant Temperature Dependent

0

100

200

300

400

500

600

700

800

900

1000

1500 2000 2500 3000 3500 4000 4500+

Amps

RPM

450A

900A

Alternator Performance Curves

6

450A Water Cooled Alternator

Brushless design.

Complies to Mil-STD-461.

Compact and reliable, weighing 40kg.

Long service life 11,000+ hours.

Designed for the harshest environments from sub-zero temperatures to desert climates.

Alternator output available from 1800RPM.

Maximum current output 450 Amps.

Factory configurable voltage and current limits.

Maximum operating speed - 10,000RPM.

Engine idle output of 400 Amps.

CAN J-1939 interface.

Specifications

Part Number: 450A-000-001

Type Brushless Permanent Magnet

Cut in Speed 1800 RPM (Alternator)

Maximum Output 450 Amps

Weight 40 Kg

Voltage Regulator Programmable, typical 28.3 Volts

Voltage Range 14 - 30 Volts DC

Operating Ambient Temperature -40° to 105 °C

Maximum Rotor Speed 10,000 RPM

Regulator Unit Integrated, Solid State.

Max Continous Output 450A

Mounting Custom

Ignition Warning Light Yes

Electrical Connection M12 (+ve), M10 (-ve)

Cooling Water Cooled

Coolant Temperature -40° to +85 °C

Coolant Flowrate >3 litres /min

7

308

150

187275


050

100150200250300350400450500

1800

1900

2000

2100

2200

2300

2400

2500

2600

2700

2800

2900

3000

3100

3200

Amps

RPM

38 C

48 C

57 C

10

3°

6x 9

105

60.2°

6X 60°Ø200 pcd

A

B

2 x 8.5 24.5M10 - 6H 20 10.1 X 90°, Near Side

100

VIEW B

277

551

87 87

68.

5

4 x 14.5 36.5M16x1.5 - 6H 32

22

0

329

VIEW A3.0°

OUTLET 2INLET 2OUTLET 1INLET 1

284

558

85

24

.6

56

6

16

0 H9

/f8

DIN 5480 - W25X2X11X7K

M16 POSITIVE TERMINAL 1 M16 POSITIVE TERMINAL 2

M12 NEGATIVE TERMINAL 1 M12 NEGATIVE TERMINAL 2

GROUND CONNECTION: 5 12

M6 - 6H 10

87.

8

100

150

30

214

R112.5

26°

145

X2 - CANVG95912 B 10-35SN

X1 - SENSEVG95234 B1 14S-6SN

TECHNICAL DATAVOLTAGE: CURRENT MAX : SPEED MAX: COOLANT TEMPERATURE:COOLANT FLOW RATE:

28V900A10000 RPM85° MAX6 L/MIN (2 *3 L/MIN) MINIMUM

2X

A - AWIC - SENSE

X1

1 - CAN H2 - CAN L3 - CAN GND.X2

(+)

(-)

REG

SCHEMATIC


Brushless design.

Meets military standards Mil STD 461, Mil STD 810 and Mil STD 1275.

Compact and reliable, weighing 80kg.

Long service life 11,000+ hours.

Designed for the harshest environments from sub-zero temperatures to desert climates.

Alternator output available from 1800RPM.

Maximum current output 900 Amps.

Factory configurable voltage and current limits.

Maximum operating speed 10,000RPM.

Engine idle output of 800 amps.

CAN J-1939 interface.

Specifications

Part Number: 900A-000-001

Type Brushless Permanent Magnet

Cut in Speed 1800 RPM (Alternator)

Maximum Output 900 Amps

Weight 80 Kg

Voltage Regulator Programmable, typical 28.8 Volts

Voltage Range 14 - 30 Volts DC

Operating Ambient Temperature -40° to 105 °C



Max Continuous Output 450A

Mounting Custom

Ignition Warning Light Yes

Electrical Connection 2x M16 (+), 2x M12 (-)

Cooling Water Cooled

Coolant Temperature -40° to +85 °C

Coolant Flowrate >6 litres /min (2x 3 litres / min)


11

3°

6x 9

105

60.2°

6X 60°Ø200 pcd

A

B

2 x 8.5 24.5M10 - 6H 20 10.1 X 90°, Near Side

100

VIEW B

277

551

87 87

68.

5

4 x 14.5 36.5M16x1.5 - 6H 32

22

0

329

VIEW A3.0°

OUTLET 2INLET 2OUTLET 1INLET 1

284

558

85

24

.6

56

6

16

0 H9

/f8

DIN 5480 - W25X2X11X7K

M16 POSITIVE TERMINAL 1 M16 POSITIVE TERMINAL 2

M12 NEGATIVE TERMINAL 1 M12 NEGATIVE TERMINAL 2

GROUND CONNECTION: 5 12

M6 - 6H 10

87.

8

100

150

30

214

R112.5

26°

145

X2 - CANVG95912 B 10-35SN

X1 - SENSEVG95234 B1 14S-6SN

TECHNICAL DATAVOLTAGE: CURRENT MAX : SPEED MAX: COOLANT TEMPERATURE:COOLANT FLOW RATE:

28V900A10000 RPM85° MAX6 L/MIN (2 *3 L/MIN) MINIMUM

2X

A - AWIC - SENSE

X1

1 - CAN H2 - CAN L3 - CAN GND.X2

(+)

(-)

REG

SCHEMATIC


0100200300400500600700800900

1000

Amps

RPM

38 C

48 C

57 C

14

Inductor Alternators

Milspec formed in April 2002 as a result of a management buyout of Australian Defence Industries Live Fire Target Systems design & manufacturing capability. As part of this management buyout Milspec gained the IP for a number of military grade alternators that were developed in conjunction with the US, Canadian and UK defence forces as part of a collaborative partnership to minimise vehicle component variations. Australia has been involved in the seamless production of military grade alternators since the 1970’s.

From those early days Milspec have taken that base line technology and developed a full range of alternators for military vehicles. Today Milspec offers a range of inductor alternators from 120 amps to 360 amps.

The development of stator winding technology and electro-magnet strength has allowed Milspec to create market leading alternators delivering world class output/kg and output/cubic meter. This performance from our inductor alternator range is replicated and enhanced through our complete range of permanent magnet alternators.

Compliant to:

• Mil STD 461: electro-magnetic defence capability standard.• Mil STD 810: environmental military standard.• Mil STD 1275: voltage capability standard for military vehicles.

If you require 120-360 amps at vehicle idle Milspec has the solution!

15

Specifications Units Alternators

Model 120A Air Cooled 300A Air Cooled 360A Air Cooled 360A Water Cooled

Type Brushless Brushless Brushless Brushless

Cut in Speed (rpm) RPM 1665 1650 1600 1600

Max Output Amps 120 300 360 360

Max Continuous Output Amps 120 285 320 340 #1

Weight KG 24 24 32 27

Voltage Regulation Volts 28.4 28.3 28.6 28.6

Ambient Operating Temp Celsius -15°C to +92°C

Maximum Rotor Speed RPM 13000 13000 13000 12000

Mounting Specific SAE J 180 SAE J 180 SAE J 180 Clamp

#1 Coolant Temperature Dependent

0

50

100

150

200

250

300

350

400

2000 3000 4000 5000 6000 7000 7500+

Amps

RPM

120A

300A

360A WC & AC


16

120A Air Cooled Alternator

Milspec’s most successful alternator with over 15,000 in service. Commissioned on the Unimog and Landrover vehicles, this unit remains available for replacement parts. This air cooled alternator has been modified from its original 100 amp output to now deliver 120 amps while maintaining its original diameter. Milspec’s engineers will work with you and your team to configure your engine in 3D CAD to align the unit to your vehicle requirements.

Specifications

Part Number: 120A-AC-001

Type Inductor Alternator

Cut in Speed 1665

Maximum Output 120A

Weight 24kg

Voltage Regulator 28.4 V

Voltage Range 26 - 30 V

Operating Ambient Temperature -40 - 93 C

Maximum Rotor Speed 13000 RPM


Max Continuous Ouput 120 A

Mounting SAE J 180

Ignition Warning Light Optional

Electrical Connection M12 +ve, M10 -ve

Cooling Air Cooled

17

In 2004 Milspec was approached by Thales to develop a 300A alternator for the Bushmaster vehicle to replace the current 100A unit.

Working closely with Thales, our alternator was designed and developed around exact requirements. Trials were conducted in the vehicle for EMC, temperature and reliability, proving that we were able to design and develop an alternator that fit into the confines available, our alternator was selected for the highly successful Bushmaster vehicle.

Given the success of our alternator in the Bushmaster, Navistar assessed our unit during the process of identifying a suitable alternator for their Husky vehicle. Navistar found that our unit was the worlds smallest military spec alternator in their capacity range. Our 300A alternator was selected by Navistar to be installed in their Husky vehicle.

Our 300A alternator is now in service with at least a dozen armed forces worldwide, with more than 1000 units of different variants in service in the Australian Defence Force.

The success of our 300A alternator has allowed us to develop our range of permanent magnet and inductor alternators to extend up to a 900A alternator. Contact Milspec today to see how we can work with you to develop an alternator to suit your needs.

300A Alternator Case Study

19


The Milspec 300A alternator has been in use in both Australian and International Defence Forces, and is currently installed and in service on the highly successful Thales Bushmaster and Navistar Husky vehicles. Manufactured and tested in-house to meet standards Mil STD461, Mil STD 810, and Mil STD 1275, our alternators are lighter than competitors and feature a double seal on the ball bearing, increasing the life span to 11,000hrs.

Specifications

Part Number: 930213-300


Cut in Speed 1665

Maximum Output 300A

Weight 24kg







Mounting J-180



Cooling Air Cooled

20

360A Air Cooled Cooled Alternator

Our 360A water cooled alternator allows the retrofit of an existing water-cooled system to the high output Milspec 360 amp unit. The technology has evolved from our highly reliable 300A air cooled unit. The fully sealed water jacket allows this unit to run up to 360 Amps with a maximum water inlet temperature of 95 degrees celsius. Using SAE J180 vehicle mount system this unit is compatible with multiple military vehicle applications. Milspec will work with you and your team to configure your Engine in 3D CAD models to align the unit to your vehicle requirements.


3RD ANGLE PROJECTION

203.20

157 PCD

68.60 339.80

30.70

8

M10

M12

VG95234

REV. DESCRIPTION EN DATE AUTHOR APPROVED01 *** FIRST DRAFT - DO NOT USE FOR PRODUCTION *** -

A

B

D

E

F

C

1 2 4 5 63

F

D

E

C

B

A

UNLESS OTHERWISE SPECIFIED:TOLERANCES

LINEAR HOLE ANGULAR ±0.4 +0.2\-0.0 ±1.0°

SHEETSIZEA3

SCALE 1:2

Milspec Manufacturing Pty Ltd.161-169 Fallon Street, Albury, NSW 2640, Australia.Telephone: (02) 6022 7100. Facsimile:(02)6040 9866.www.milspec-manufacturing.comACN 100 161 582.

© 5.5.05 MILSPEC MANUFACTURING PTY LTD OWNS THE COPYRIGHT TO THISDRAWING WHICH IS ITS EXCLUSIVE PROPERTY AND WHICH IS SUPPLIEDIN CONFIDENCE AND WHICH MUST NOT BE USED FOR ANY PURPOSEOTHER THAN THAT EXPRESSLY PERMITTED IN WRITING BY THE OWNERSAND MUST NOT BE DISCLOSED OR PRODUCED WITHOUT PERMISSION FROMTHE OWNERS IN WRITING. THIS DRAWING MUST BE RETURNED TO THEOWNERS WHEN THE PURPOSE FOR WHICH IT IS SUPPLIED HAS CEASED.

CAT No.360A Water CooledSHEET 1 OF 1

DRAWN TO AS1100. IF IN DOUBT-ASK.DO NOT SCALE.

REMOVE BURRS AND BREAK SHARP EDGES.

DR: REQ 18/04/2016CK: 25/09/2013

MANUFACTURINGMilspec

TITLE:

Specifications

Part Number: 360A-WC-001


Cut in Speed 1600

Maximum Output 360A

Weight 26kg







Mounting Clamp



Cooling Fluid

Coolant Temperature -40 - 85 C

Coolant Flowrate 3l/min

21

As vehicle manufacturers struggle to meet military requirements for power at vehicle idle in a finite space, Milspec developed the 360A air cooled unit. This unit offers maximum capacity by volume over all of our inductor alternators. It uses the SAE J180 vehicle mount system which makes it compatible with multiple military vehicle applications. Milspec will work with you and your team to configure your engine in 3D CAD models to align the unit to your vehicle requirements.


Specifications

Part Number: 360A-AC-001


Cut in Speed 1600

Maximum Output 360A

Weight 28kg






Max Continuous Ouput 330A

Mounting J-180



Cooling Air Cooled

22

Milspec’s Portable Power product range has developed as a result of our experience in

designing and manufacturing military grade alternator products. This alternator technology

was leveraged to produce a high performance, low weight range of units designed to meet

MIL STD 461 and tailored to meet numerous applications. Milspec is working with world

leading diesel and hydraualic technology companies to deliver a state of the art product to

our customers. Contact Milspec today to see how we can meet your Portable Power needs.

MILSPEC Portable Power

C4I KITS

AUXILIA

RY POW

ER UN

ITS

PORTA

BLE D

ISTRIBUTIO

N U

NITS

23

Hydraulic DieselLength 700mm 700mm

Width 280mm 400mm

Height 280mm 600mm

Weight 38kg 166kg

Output Voltage 28Vdc 28Vdc

Output Current 300A 300A

Output Power 8.4kW 8.4kW

Fuel Consumption N/A 265g/kWh

Length 720mm

Width 490mm

Height 620mm

Weight 145kg

Output Voltage 28Vdc

Output Current 430A

Ouput Power 12kW

Fuel Consumption 212g/kWh

Length 1650mm

Width 650mm

Height 800mm

Weight 380kg

Output Voltage 28Vdc

Output Current 800A

Ouput Power 22.4kW

Fuel Consumption 212g/kWh

MILSPEC APU-H-8.4/D-8.4

MILSPEC APU-D-12

MILSPEC APU-D-22

Enquire [email protected]

Visit www.milspecmanufacturing.com

Milspec Manufacturing Pty. Ltd. 874 Knight Road, Albury NSW 2640 Telephone +61 2 6022 7100 Facsimile +61 2 6040 9866

Length 330mm

Width 200mm

Height 100mm

Weight 5kg

Input Voltage 20-36Vdc

Output Power 100W @ 12V

THALES PDU

MILSPEC 120 kVA PDU

MILSPEC 60 kVA PDULength 940mm

Width 450mm

Height 555mm

Weight 70kg

Input Voltage 415V

Output Voltage 415V

Length 1152mm

Width 550mm

Height 600mm

Weight 80kg

Input Voltage 415V

Output Voltage 415V

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