Design of Copper-Clad Aluminum Winding Alternator for Vehicle Application

Abstract

Copper-clad aluminum wire which is composed of aluminum core clad with ETP copper was exploited to solve the problem of the copper price increasing by replacing traditional copper wire with copper-clad aluminum wire in the alternator for vehicle application. The aluminum winding alternator parameter was designed and the alternator was tested. The test data show that copper-clad aluminum can offer most of the advantages of aluminum, such as having lighter weight and lower cost than copper, but without the main perceived disadvantages of aluminum. With right parameter and well welding, aluminum winding can replace copper winding to reduce the alternator cost.