Alternator assembly

A method of modifying a brushed alternator for vehicles, wherein the brushed alternator comprises:

• a housing assembly including a first portion, and a second portion having a plurality of electrical connectors and having an aperture;
• a cylindrical stator supported at least partially by the first portion of the housing assembly;
• a rotor assembly including first and second slip rings, and including a drive shaft configured to rotate about an axis, the drive shaft having first and second ends;
• and a removable brush assembly removably mounted to the housing assembly, a resistor, and brush blocks configured to support brushes for engagement with the slip rings, to pass a force current through the rotor assembly via the slip rings, the method comprising the steps of:
• removing the brush assembly mounted to the housing assembly;
• removing the rotor assembly and replacing said rotor assembly with a replacement claw pole rotor assembly having a pair of opposing pole pieces, the replacement claw pole rotor assembly defining an axis of rotation along a drive shaft of the replacement claw pole rotor assembly, each of the pole pieces having a plurality of circumferentially spaced pole fingers extending axially, the pole fingers of the pole pieces alternating between north and south magnetic polarities upon energization of a field coil;
• positioning a field coil coaxially within an internal cavity of the replacement rotor assembly to arrange the field coil in a spaced apart relationship relative to internal walls defining the internal cavity of the replacement rotor assembly wherein the field coil comprises an axial surface that is spaced away from inner walls defining the internal cavity of the rotor assembly;
• and a medial surface of the field coil that is substantially transverse relative to the axis of rotation wherein the medial surface is configured for being mounted to the housing assembly;
• positioning the cylindrical stator to envelop the pole pieces, the cylindrical stator being arranged coaxially relative to the drive shaft;
• positioning the housing assembly to surround the cylindrical stator with the drive shaft of the replacement rotor assembly being supported by the housing assembly;
• and
• fixedly mounting the medial surface of the field coil to the housing assembly.