How It's Made - Alternators - Generator Heads

Portable Diesel Generators

Here is a look at how the alternators are made for our portable diesel generators.  We are one of the only companies that meets UL and CSA standards and has the electrical certification to prove it.  Most generators sold by other companies in North America follow no electrical standard and do not meet electrical safety codes. Ones that do not have approval from a nationally recognized testing laboratory should be avoided. 

Many companies that sell those types of generators without electrical approval have purchased their alternator from suppliers who use the absolute minimum quality the can get away with.  This is done to lower costs and increase sales. 

Aurora Generators is involved in the design, manufacturing and the assembly process. We have our own quality control and oversee production. We built to much higher standards then others. This is how you can tell.

Our portable generator products bearing the ETL Listed Mark meet the minimum requirements of prescribed product safety standards. The ETL Listed Mark is the legal equivalent of the UL Listed and CSA Listed Marks throughout the United States and Canada. For over 100 years, dating back to Thomas Edison’s Electrical Testing Laboratories (ETL), “ETL” has been a leader in electrical safety compliance.  They certify our portable diesel generators.  Our portable diesel generators have been approved to CSA Standard 22.2 No. 100 These higher standards insure you are purchasing a safe and superior product over others.

Here are some images from our Alternator manufacturing and testing. 

Alternators are all build in-house. Machines like this insure winding accuracy and a balanced rotor.
Just like on a car tire, if it is not balanced then there will be vibrations.  Most companies do not have these types of machines.
Portable generator alternators turn at 3600 RPM. The vibrations are transferred to the alternator and engine bearings.

The stator and rotor is measured for resistance, inductance and capacitance.
Testing every single component help to insure there is no break in insulation and the quality meets our higher standards. 

Production lines may have to fill some big orders so having plenty of parts in stock and assembled alternators ready to go is important.

This rusty looking thing is a load bank.
This load bank is one of many. It is a series of metal plates that are connected to generators output and lowered into a salt water pool.
The more it is submerged the lower the resistance and higher amount of current / load  on the generator.
How the engine and alternator responds to these changes is monitored and part of our quality control.