MIL-SPEC Lightweight Diesel Generator

APC Technology partnered with a South Australian generator manufacturer with over 30 years of experience to fulfill a project for the Australian Defence Forces. While the manufacturer possessed extensive expertise in generator construction, they did not have the specific knowledge required to meet the project’s stringent defence specifications.

APC Technology, with its proven understanding and application of defence standards, played a critical role in the project. By combining advanced engineering expertise with the manufacturer’s construction capabilities, APC Technology designed a highly compact, powerful, and user-friendly generator solution tailored for defence applications. This collaborative approach ensured the final product met both operational and compliance requirements while maintaining efficiency and durability.

Achieving a Lightweight and Compact Design

APC Technology’s engineering team carefully evaluated multiple design options to significantly reduce the generator’s overall weight without compromising performance. Ultimately, they selected an aluminium frame instead of traditional steel construction. Aluminium has a much lower density, approximately three times lighter than steel, making it ideal for lightweight, transportable defence equipment.

This weight reduction is particularly important in military applications where mobility, rapid deployment, and ease of transport are critical factors. Lighter systems also reduce logistical costs and improve handling across various terrains.

To further optimise the generator’s size and efficiency, the team selected a 3000RPM engine instead of the conventional 1500RPM option. This decision enabled a more compact footprint while still delivering the required power output, ensuring the generator could fit seamlessly within strict dimensional constraints.

Additionally, modern diesel generator technologies continue to evolve with improvements in fuel efficiency, power density, and electronic control systems, enhancing both performance and remote monitoring capabilities. 

The Value of In-House Capabilities

APC Technology’s strong in-house engineering and testing capabilities played a vital role in ensuring efficient project execution and compliance with defence standards. The initial design included electrical box components that were not rated for the required low-temperature environments.

By leveraging its in-house thermal chamber, APC Technology conducted rigorous environmental and confidence testing, enabling the team to validate and certify components for operation in extreme cold conditions.

For shock and vibration testing, APC Technology utilised SolidWorks Simulation software to perform advanced finite element analysis (FEA). This allowed for precise virtual testing of structural integrity under harsh transport and operational conditions.

This approach eliminated the need for external compliance testing facilities, reducing both project costs and lead times while maintaining high engineering accuracy and reliability. The ability to perform testing internally also ensures faster iteration, improved quality control, and greater flexibility in meeting unique client requirements.

Daronmont Bespoke Generator Specifications:

• Compact footprint: 2.438m W x 1.5m H x 0.9m D
• Compliant to ISO 1161 (shipping container mounting)
• Designed for extreme temperatures: -32°C to 49°C (arctic to desert)
• Operational up to 5,000 ft altitude
• Suitable for hot and humid environments (28°C at 95% humidity)
• Dust and water resistant (IP55)
• Lightweight aluminum frame (~1200kg)
• Shock and vibration resistant for all transport modes
• Long-lasting fuel efficiency (8 hours full load runtime)
• Quiet operation (<75 dB under full load)
• Power output: 40KW @ 0.8 power factor (50KVA)
• Low power operation: 15KVA continuous
• Outlets: 2x 400V, 2x 230V
• Network connectivity: monitor/stop/start via network

These specifications highlight the generator’s ability to deliver high-performance power generation while maintaining portability, durability, and operational efficiency. Features such as IP55 protection and vibration resistance ensure reliability in harsh field conditions, while network connectivity enables remote monitoring and control—an increasingly important capability in modern defence and industrial systems. 

“Duncan Groome, Chief Engineer said “APC’s deep understanding of generator design and their impressive support and proactive responses were invaluable throughout the project.”

To read more about out Environmental Testing  and Capabilities or speak to an expert on 08 8363 0400.