Custom and UAV Generators and Starters

UAV Systems

Sullivan is the leader in UAV generators/alternators. We were the first to manufacture a commercial generator for unmanned R/C aircraft, and that experience has developed into an extensive generator program.

We can design and build a generator for nearly any size unmanned aircraft. We have made them as small as 0.25 watts and as large as 1000 watts. The types we build are very reliable and efficient. They are direct drive, which eliminates a drive train, and have no sliding electrical contacts. They mount on the propeller shaft or on a rear output shaft, which usually helps with weight balance and minimizes the physical envelope.

We design each unit for the engine and power required. We start with your system requirements and constraints, then design any parts or electronics that are application specific. We have several frame sizes and are often able to use an existing lamination or magnet set. We then fabricate the required parts, assemble the units, and test the systems.

We can provide more detail as well as suggested options for your specific project. Just email us and let us know what you need.

Standard Genesys Generator

Standard Genesys magnet ring and coil

Genesys was the first practical generator for model engines. Developed in the early 1990s, it is basically an inside-out 5 watt alternator. The system features rare earth magnets and a no-moving-parts design for reliability and light weight. It is rated for 5 watts. If you need more power, you can add a second coil. This will increase maximum power to 10 watts. This will require a new mounting bracket, which you will need to design and fabricate, as each engine is a little different. You can download a schematic for multiple coil hookup.

From 5 to 20 watts we can either extend the standard unit or design a custom unit. Above 20 watts the best solution is a pancake type. The pancake types can be scaled to several thousand watts.

Many applications have fall into the 10 to 20 watt category. This model is a 20 Watt version, and incorporated an Adjustable Motor Mount. It was designed to fit .60 to .90 size engines, using a 3" magnet ring. It is an extension of the standard model.

This Custom 4" magnet ring and dual coil bracket is another extended standard type. It fits a Zenoah® G45 and Zenoah® G62. It produces 10 watts.

This is a Magnet ring and Regulator box from a 30 watt unit. It fits a small 3W® engine. Although it is an extended type, it has a custom regulator to handle the additional power.

Larger Custom Generators

Over a certain wattage size, we build Pancake Alternators. They are very efficient, simple, reliable (only one moving part, a ball bearing) and powerful for their size and weight. We design and fabricate these to the customers' specific engine, RPM, wattage and regulated voltage(s) requirements. We have built these from 30 watts to 1000 watts. They utilize Neodymium magnets for high energy densities.

Some examples are:

This is a 150W Generator mounted on a 3W-150® engine.	This is a 300W Generator mounted on a 3W-100® engine.
This generator is on a ZDZ-160 and is capable of 300-500 watts.	This is the back of a 300 watt unit.
	This is a 150W Dual Voltage Cascade Regulator This is a 300W Dual Voltage Parallel Regulator
This is a 4" 50W Generator

Starters and Generators

Another group of custom products involve combination starter/generators. Some vehicle operations call for remote starting. Depending on the generator wattage required, it can be lighter to have a single unit than to carry separate onboard starters and generators.

If it is better to have separate units or if the starter will not be onboard, we can also design both a starter and a generator for the same vehicle. One unit we made had a quick release starter that attached to the launch frame. In operation, the vehicle was remotely started by an operator, and the vehicle was launched when the engine reached operational speed. The vehicle pulled away from the starter during launch.

Small 25 Watt starter/generator using a two speed transmission.

If you have a project in mind, call or email us and we can discuss if one of these units may be practical for you.