Why would market stators be better

[HotRock]

Any opinions or factual information as to why after-market stators may be better than OEM.
Why does the insulation on the windings break down?  Heat?  Reasons for overheating?
Is HD stator insulation on the wire inferior? 

[Ridetard]

Sometimes they use a heavier guage wire.  This will help prevent over heating which leads to stator failure.

[autoworker]

If you are in the market for charging system parts these people can answer your questions.
http://www.cycleelectricinc.com/
They are  good outfit to deal with.

[springer-]

Any opinions or factual information as to why after-market stators may be better than OEM.
Why does the insulation on the windings break down?  Heat?  Reasons for overheating?
Is HD stator insulation on the wire inferior? 

I don't believe the HD wire insulation is inferior in any way.  Heat is certainly a factor as well as oil and the overall harsh environment.  Add to that stress on the electrical system with higher wattage lights and other additional electronics that draws more power and failure could be right around the corner.

If you are in the market for charging system parts these people can answer your questions.
http://www.cycleelectricinc.com/
They are  good outfit to deal with.

Cycle Electric stators may be better but IMO it is the use of their entire system that is better.  The CE regulator for example only delivers what power it needed.  As the load increases the CE charging system delivers more current.  The Stock, and most aftermarket systems, have a constant rate.  This is due to the method used in the regulator and this keep the stator at maximum output all the time.  IMO, this can reduce its like expectancy because it is under full load all the time (more stress).  Also it robs power from the engine maintaining the full load.  Since the CE system varies the load as needed, the stator is not worked as hard and the engine doesn't have to work as hard to turn it.  ASAIK, the Cycle Electric system is the only one that works this way.

[Ken R]

Any opinions or factual information as to why after-market stators may be better than OEM.
Why does the insulation on the windings break down?  Heat?  Reasons for overheating?
Is HD stator insulation on the wire inferior? 

I don't believe the HD wire insulation is inferior in any way.  Heat is certainly a factor as well as oil and the overall harsh environment.  Add to that stress on the electrical system with higher wattage lights and other additional electronics that draws more power and failure could be right around the corner.

If you are in the market for charging system parts these people can answer your questions.
http://www.cycleelectricinc.com/
They are  good outfit to deal with.

Cycle Electric stators may be better but IMO it is the use of their entire system that is better.  The CE regulator for example only delivers what power it needed.  As the load increases the CE charging system delivers more current.  The Stock, and most aftermarket systems, have a constant rate.  This is due to the method used in the regulator and this keep the stator at maximum output all the time.  IMO, this can reduce its like expectancy because it is under full load all the time (more stress).  Also it robs power from the engine maintaining the full load.  Since the CE system varies the load as needed, the stator is not worked as hard and the engine doesn't have to work as hard to turn it.  ASAIK, the Cycle Electric system is the only one that works this way.

HD charging systems haven't been the "shunt" type for many years.  They regulate just like Cycle Electric.  However, C.E. regulators do have thermal protection that stock don't.  If the regulator innards get to 100C, the regulator shuts off until the heat goes down.  One can see this effect in hot weather stop and go traffic.  They need air flowing over the fins of the regulator to keep 'em cool.

One thing I have noticed about all stator failures I've seen:  They all fail (short and burn) at the 10 o'clock to 12 o'clock winding positions.  I wonder if cooling oil doesn't get splashed up there.  I've only seen about a dozen, but every one of them had failed in the same area.  Windings  within the 12 o'clock to 6 o'clock positions were usually not even discolored in the small sample I've seen. 

[Admiral Akbar]

They all fail (short and burn) at the 10 o'clock to 12 o'clock winding positions.

Isn't that where the external wires connect?  Max

[HotRock]

So if HD is a shunt system that means that the stator output that is not needed is routed back to ground.  In that case it would not matter how many electrical accessories were added if the circuit is running at full output anyway.   

Cycle electric claims their insulation on wire is rated at a much higher temperature than the stators from HD.  So who makes the HD stators.    CE also claims to have a tighter winding that disipates heat more efficiently.  Sounds reasonable.

I think a thinner primary lube will also provide a better cooling effect.  Just actually how much lube can get to the stator since it is fully, or almost fully enclosed by the rotor?   I think not much.  ?   

[Tsani]

That is where the output taps are made on the stator and that would be the weakest point. If the taps are not 100%, you could have a high resistance connection and more heat, which will cause a failure at some point.

[Admiral Akbar]

In that case it would not matter how many electrical accessories were added if the circuit is running at full output anyway.   

Yep but that power wouldn't have to be dissipated in the regulator. It would be in the accessory..

Cycle electric claims their insulation on wire is rated at a much higher temperature than the stators from HD.

It's probably wound for a higher voltage since the alt / reg system is wired  series open instead of parallel shunt..

Just actually how much lube can get to the stator since it is fully, or almost fully enclosed by the rotor?

I would thing that at 35 to 60 RPS the oil would be flung out from inside ..  Not sure thinner is any better.. Max

[Admiral Akbar]

It's probably wound for a higher voltage since the alt / reg system is wired  series open instead of parallel shunt..

BTW it would be interesting to figure out what dissipates less energy in the alt.. I'd think series open.. Max

[Ridetard]

They all fail (short and burn) at the 10 o'clock to 12 o'clock winding positions.

Isn't that where the external wires connect?  Max

No, dont tell them Max...  It's a secret

[HotRock]

I do not understand the theory of series open or parallel shunt.   I'm of the old school and don't like solid state circuitry, I suppose mainly because I just never learned it.  LOL   I do understand basic electronics pretty good.
After reading the technical section in Cycle Electrics website I would be convinced to purchase their stator should I ever need one.

Max, I read a report once about the cooling effects of heavy vs. light oil.   That particular report said that a lighter oil carried heat away faster than thicker oil.   ?  I don't really know for sure, but I run the thinner ATF for that reason.

[Admiral Akbar]

Those types, "series open or parallel shunt",  are not theories but circuit topologies..

I'm of the old school and don't like solid state circuitry,

If that were the case you should still be running a generator..  Alternators need solid state..

That particular report said that a lighter oil carried heat away faster than thicker oil.

Not sure as to the mechanism that might cause this but would 10w30 be that much different than 20w50?

Max

[HotRock]

Ha ha, no Max, no more generators for me.   Neither the giant Liece Neville alternators and the giant selenium rectifiers we used to use on cop cars. 

[cheetah]

So if HD is a shunt system that means that the stator output that is not needed is routed back to ground.  In that case it would not matter how many electrical accessories were added if the circuit is running at full output anyway.   

Cycle electric claims their insulation on wire is rated at a much higher temperature than the stators from HD.  So who makes the HD stators.    CE also claims to have a tighter winding that disipates heat more efficiently.  Sounds reasonable.

I think a thinner primary lube will also provide a better cooling effect.  Just actually how much lube can get to the stator since it is fully, or almost fully enclosed by the rotor?   I think not much.  ?

HD type regulators shunt only the voltage to ground.
Think of voltage as pressure and amperage as volume and you can get a mental picture of what is happening.
The higher voltage (pressure), the more amperage (volume) is pushed through the system.
C