Alternator

This design/build project enabled a manufacturer of after-market specialty automotive hardware to expand their product offering and profitability.

In this case, customizations were made to a high-reliability alternator body such that it could be used across many vehicle platforms, thereby improving upon the OEM product performance.

Challenge

For a client in volume production of specialty automotive hardware, our challenge was to adapt a standard alternator design to accommodate a series of mounting arrangements all while optimizing the design to minimize the number of machining steps.

Solution

•  created a 3-D ‘as-built’ CAD model of the existing product using SolidWorks® software
•  reviewed the applicable SAE automotive design standards
•  changed the shape and features of the mating parts while maintaining structural integrity, part functions
• output the model to a CAM station to prototype and ultimately mass-produce the parts on a Deckel Maho DMC 64V Linear milling center

Services/Skills

•  3-D CAD modeling
•  Mechanical Engineering
•  Mechanical Design
•  DFM (Design for Manufacture) principles

Results

The completed design enabled this manufacturer to mass produce a series of assemblies on a common platform, and with the parts optimized for their machining process profitability was enhanced.