What are the differences between a small D.C. alternator and D.C. generator?

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An aircraft 60A DC generator and 60A DC alternator are pretty much the same size and weight (the gen is a little heavier).

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In a generator, you are rotating a winding (the armature) through a magnetic field. So all of your power has to come through the commutator brushes (which also rectify the current to DC). This means the brushes wear out faster and have to be inspected every 200hrs. Also, in addition to a voltage regulator, a generator needs a current limiter and a reverse current cutout. Also a generator will not produce full power until about 50-60% of max RPM.

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An alternator rotates the field inside a stationary winding. So only the field current goes through the brushes which last much longer (500hrs for inspections). A voltage regulator controls the field current like on the generator and a diode rectifier converts the AC to DC. The current is self limiting and the diodes prevent any reverse current.

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An alternator creates A.C. voltage that is converted to D.C. voltage by a rectifier bridge made of diodes. A generator just creates D.C. voltage but must be of much bigger size and weight to generate the same current and voltage as an alternator. Hope this helps.
-Jeff

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