AC Brushless Generator Overhaul

Posted by Jacek Laszkiewicz on Jan 24, 2024

Recent Project: Comprehensive Overhaul of AC Brushless Generator

We're proud to announce the successful completion of a scheduled 50,000-hour overhaul on an 810 KW Kato DP Synchronous AC Brushless Generator. This meticulous process involved a series of intricate steps to ensure optimal performance and longevity:

  1. Initial Assessment: Conducted thorough visual inspections and operational tests, followed by careful dismantling.
  2. Component Refurbishment: Employed proven cleaning methods to preserve the integrity of all parts, focusing on the rotor and stator's condition, and meticulously steam cleaned and oven-dried components.
  3. Advanced Testing & Treatment: Executed a series of electrical tests (IR, winding resistance, polarization index, surge comparison), alongside mechanical inspections of critical parts. All windings received a varnish treatment and oven cure for enhanced protection.
  4. Precision Balancing & Final Assembly: Achieved dynamic balance for all rotating components to ISO G1 specifications, followed by reassembly, hardware torque application, and comprehensive sealing and painting for lasting durability.

Understanding Brushless Generators: A Blend of Innovation and Efficiency

Brushless generators stand at the forefront of electrical generation technology, merging reliability with efficiency. These generators capitalize on electromagnetic induction, a principle championed by Faraday, to transform mechanical energy into electrical power without the drawbacks of brush wear and maintenance.

  • Core Components:
    • STATOR: The static powerhouse with embedded windings.
    • ROTOR/ARMATURE: The dynamic heart, spinning within the magnetic field to generate electricity.
    • RECTIFIER: The bridge converting AC to DC, ensuring a steady power output.
  • Advantages:
    • Enhanced lifespan and reduced maintenance, thanks to the absence of brushes.
    • Higher efficiency and operational cost savings.
  • Challenges:
    • Initial cost and complexity, requiring specialized knowledge for repairs.


Our recent project underscores our commitment to excellence and our deep understanding of advanced power systems. As we move forward, we remain dedicated to harnessing technology to deliver top-tier service and innovative solutions in the realm of electrical generation.

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