How it's made - Whole Home Generators

How do you know when your shopping for a home generator what you are really getting?

On the outside they can all look the same. Aurora Generators takes you on a walk through the manufacturing process so you can see just what is involved and how it's made. There is no mass production. Real people power goes into making each generator. Everyone involved in the manufacturing of Aurora Generators are dedicated and professional. We all take pride in our work and the quality of our products.

Laser cutting machines are used to cut materials that are used in the manufacturing process. Laser cutting works by directing the output of a high-power laser, by computer, at the material to be cut. The laser leaves an edge with a high-quality surface finish. The advantages of using laser over mechanical cutting is higher precision, cleaner edges and the ability to design custom shapes and cutouts that would not normally be possible with traditional cutting methods.

Press brake forming. This is a form of bending, used for long and thin sheet metal parts. The machine that bends the metal is called a press brake. The lower part of the press contains a V shaped groove. This is called the die. The upper part of the press contains a punch that will press the sheet metal down into the v shaped die, causing it to bend. The backgauge allows the operator to make a series of bends in a component to a high degree of accuracy. Some of the ones used are also computer controlled.

Precision welding being performed by one of many workers used in construction of our generator enclosures.

Design and fabrication of exhaust systems are all performed in house. Having control over materials and conception lets us make better use of space and increase performances while reducing overall noise levels.

Fuel tank is built into the generator base.

After a acid wash is used to clean the metals before they are sent off to be painted.

Acoustic foam insulation is used throughout the generator to reduce noise

High temperature insulation wool, commonly referred to as ceramic fiber, a ceramic material, is manufactured from alumino silicate glass which is used for thermal insulation. It is also used inside custom made exhausts our generators it can withstand temperature applications and processes up to 700 °C. / 1292 Fahrenheit.

Most of our hardware, hinges and fasteners are all stainless steel. Your generator is built stronger made to last longer.

High quality hinges are also stainless steel and heavy duty. Watch our video and see how these hinges let you remove our doors for easy access to the engine compartment if you are limited in space.

These are how the engines arrive at our factory. Each one includes a detailed report on the results of factory testing. Both three cylinder and four cylinder diesel engines are used depending on what size generator we are matching them with.

We choose Dingol alternators because they are one of the only manufactures with UL and CSA approval. All copper wiring and high grade insulation. NEVER in our history has a alternator ever failed.

Because the engines have been factory tested, there are still some fluids remaining in them. We remove everything and change a few components. The oil pressure sensor and water temperature sensor are swapped out and some other component are added like our own valves and electric fuel shut off switch. From this point everything is moved and positioned on the base of the generator using special rubber engine mounts.

A radiator is added and secured. We use a larger one then the engine supplies. Our larger radiators insure the engine can run full time in the enclosure and ever overheat.

Other component are introduced into the assembly after having been partly assembled like the doors with the hardware attached and insulation added.

Wiring of the engine sensors, glow plugs, starter, alternator and control panel.

More photos to follow.......