ECHARGING SYSTEMF

ECHARGING SYSTEMF

--

ECHARGING SYSTEMF

(CHARGING SYSTEM)W


W

W W
J
J
J
J
J
J
J
J
J
J

W
H

--

ECHARGING SYSTEMF

ECHARGING SYSTEMF

EIntroductionF
EF

K
K

WEF
E JEF J J JF

--

ECHARGING SYSTEMF

EImportance of Automotive Charging SystemF

EF
K

K
K

K
K

E F
K
W
KEF J
E F J
K
J
K
F J
KE
K J

ECharging System ComponentsF
WEF
K
K

--

ECHARGING SYSTEMF

K
K
E FK(electrical output)
K

WEF

WEF
W(Electrical Generator) J
K(Direct-current (DC) Generator)? ?
?? ?
K(Alternating-current (AC) Generator)?
K
W(Voltage Regulator) J
K
W(Generator Belt) J

K

--

ECHARGING SYSTEMF

(voltmeter)(ammeter)W(Charge Indicator) J
(indicator or warning light)
K
W(Charging System Harness) J
F
KE
W(Battery) J
K
W(Ignition Switch) J
K

ETypes of Electrical GeneratorsF

(electricity-generating plant)
K
KE F
K
K
F
KE

(Direct-current (DC) Generators) J
(conventional) ?
K E F

K
K
K

--

ECHARGING SYSTEMF

(Alternating-current (AC) Generator) J

K
F?
K(Three-phase generator)?E
K? ???(Alternator)
K

(Conventional DC Generators)
K

K

(DC Generator Construction) J
WEF
W(stationary stator frame) J
K
(rotating armature)W(armature) J

KEF
KW(terminals) J
W(commutator)EF J

K
W(commutator end shield) J
KEF

--

ECHARGING SYSTEMF

W(drive end shield) J

K
W(pole shoe) J
K
W(excitation windings) J
K

WEF
J J J JF
J
J J J J
E

W(brush holder and carbon brushes) J
K
W(pulley with fan) J


K

--

ECHARGING SYSTEMF

W(regulator) J
K

K

KE FEF

K(stationary stator)
K

(DC Generator Operating principle) J

K

K

KEFK
K

K

K
EF
E(I) (n)F
W

EF J
K

--

ECHARGING SYSTEMF

KEF
EF J
K
EF J
E F
K

WEF
JF JF
E J

(DC Generator Disadvantages) J

K
W
K J
F J
KE
J
K

--

ECHARGING SYSTEMF

J
KE F
F
KE
K J
K J

--

ECHARGING SYSTEMF

W
EALTERNATORSF


K
K(Alternators)? ?

(Importance of Alternators)

K
EF
EFK
E F

WEF

--

ECHARGING SYSTEMF

WEF


K

K


K
(semi-conductors)

K
(fixed rectifier diodes)


K
(alternator)
EloadsF(battery)

--

ECHARGING SYSTEMF

KEF
(3-phase current)E F

K
K

WEF

(alternator)
WK
K J
J
K
K J
K J
J
KEF
K J
K J
K J

EPrinciples of Alternator OperationF
(alternator)
--

ECHARGING SYSTEMF

(coil)K(electromagnetic induction)
K(induced voltage)(magnetic field)
W
K J
K J
(DC generator)

KEFEF
(AC generator or Alternator)
(rotor)

K(stator)
EF
K
K
K(magnetic flux lines)
K

EF
EF K
EFEF
K

WEF
EF

K

--

ECHARGING SYSTEMF

K EF

WEF

W
K J
J
K
K J
E F J
K
EF
(S)EFK
K
(N)
KEFKEF

EF

K
K

--

ECHARGING SYSTEMF

WEF
EA, BF

E
F
W
K J
K J
K J
K

(Alternator)
K
K EF
(Rotor)? ?(Alternator)
?(Stator)??
(S)(N)K(Stator Windings)?
F

(two brushes)
FEAC
EFKE(two slip rings)

--

ECHARGING SYSTEMF

(rectification)K(DC)
K(Diodes)EF

WEF

EConstruction of an AlternatorF

K
EFEFK
(claw-pole alternator)
(compact diode assembly)

W KE F
W(Collector-ring end shield) J
K(slip rings)

W(Rectifier)
J

KE F
KEF

EFEFEFEF
K EF
K

--

ECHARGING SYSTEMF

WEF
J J J J
JF

EEF J J J J J

WEF
EF

--

ECHARGING SYSTEMF

E
FW(Power diode)EF
J
FKEF
E
K
FW(Exciter diode)E F J
E
KEF
(Regulator, Brushes holder, and Carbon J
WBrushes)
K
K

K
(stator windings)W(Stator) J
KE F(rectifier) (three-phase)

K
EFW(Rotor) J
(two (claw poles)

Kcollector rings)
K(excitation winding)
KEF
EF
F
(N)FKE
E(S)
(S)(N)
KEF
--

ECHARGING SYSTEMF

EWWFWEF

W(Fan) J
EF
KEF
W(Pulley) J
K(belt drive)

K
W(Drive end shield) J
K

WWEF

W

--

ECHARGING SYSTEMF

WWEF



W

ETypes of Stator Windings ConnectionsF

K
K
W
E(WYE)(star)FY J
F J
E
K
(small air
Kgap)

K

--

ECHARGING SYSTEMF

(Star (Wye) - connected Stator Windings)EYF J

EF(Y)

K
K
K (Y)

(Y)K

K
F
K(neutral junction)E FKE

(Y)WEF

(Delta - connected Stator Windings)EF J
FEF
E

K

--

ECHARGING SYSTEMF

KE F
K


EF
EYFFEYF
KEFEE{ XFEF

EFWEF

WEF

EWYWF

--

ECHARGING SYSTEMF

(U-I Relationship) J

W(Y) J J
Ephase voltageFEF(U)(alternator voltage)
EF{E 3 FE
F(Up)
K(Ip)EphaseF(I)(alternator current)
W

U = U p . 3

I = Ip

--

ECHARGING SYSTEMF

W
EFZUpEF ZU
EFZIpEF ZI
(phase)p

WEF
EEFu, v, w YWWF

W() J J
Ephase currentF(U)(alternator current)
(Ip)Ephase currentFEF(I)(alternator current) K(Up)
KEF{E 3 F

U = U p

I = I p. 3

W
EFZUpEF ZU
EFZIpEF ZI
(phase)p

--

ECHARGING SYSTEMF

EERectifying Alternating Current (ACF

(positive pulse)
(wave form)K(negative pulse)
K(sine wave)??
K
K
(N)
(negative voltage) K(positive voltage)
(S)
K
K(single-phase voltage)

KEF

WEF
(three-phase voltage)EF

K(DC)(AC)
F(AC)(rectification)
KEF(diodes)E

--

ECHARGING SYSTEMF

WWWEF
EWbEFWaF

W
EFEFEFW(power diodes) J
F??
K KE
EFW(exciter diodes) J
KEF
K

KEF(diode trio)??

KEF

(Half-wave Rectification) J

E
FEF

KEF

--

ECHARGING SYSTEMF

E
F
KEFEF
(half-wave rectification)
KEFEF

WEF
EWWF

(Full-wave Rectification) J

F
EFE
EFK
K(full-wave rectification)??
EF
EF(Y)
K
EB+FEF
(positive half-waves)KEBF
(negative half-waves)E F
E F
KEF

--

ECHARGING SYSTEMF

(Y)WEF
EWWF
J J J J JF
E
EE FWUGWUpWUwF

WEF
J JF

--

ECHARGING SYSTEMF

Eu, v, wEF J
EF
EF(Y)
K EF

KEF
K(slightly rippled rectified voltage)
K(Ueff)E F K

K

(Reverse-current Block) J

K(reversed-current block)
E F

K K

EThe Circuits of the AlternatorsF
W
EFW(Pre-excitation Circuit) J
(Excitation or Self-excitation Circuit) J
(Alternator or Main Circuit) J

K (Y)

--

ECHARGING SYSTEMF

(Pre-excitation Circuit) J
EFEF
(d)EF(IB)
EF(G) KEF
K(d)EF
K
WK W

K
(a) (c)EF
K
K E{Z{XF
K EF

WEF
E W WF
JWdWcWbWa JF
J
E J J

--

ECHARGING SYSTEMF

(Alternator Warning Lamp) J J

K
EF

KEF

K
EF(G)
K

K
W

K

WEF
E W WF
JWdWcWbWa JF
J
E J J

--

ECHARGING SYSTEMF

(Excitation (Self-excitation) Circuit)EF J

(d)EF
(u, v, w)
K

EDFF
EDFK

KEF(1c)

(D+)KEF
K(DF)
K

KE F
EF K
K
K

K

(Alternator Circuit (Main Circuit))EF J

EF KEF
KEF
W
KEF(u)(w)(v)
(1b)(v)WEF

--

ECHARGING SYSTEMF

E FEBF (B+)
KEF(w)(1c)
EFW
(v, w)KE(u)(v, w)F
(1b)
K(1c)EF

E FWEF
E W WF
JWdWcWbWa JF
J
E J J

(u, v, w)WEF

--

ECHARGING SYSTEMF

E15B+FK
K
K


K

EAlternator DriveF
KEF
(V-belt)(V)(drive belt)
K(flexible coupling)

WEF





W

--

ECHARGING SYSTEMF

K J
K J
(V)
(two pulleys) K


EF
KEF
K
(open flank)(V)
(transverse rigidity)EF
(V-belt tension)K
(alternator bearings)
KEF
K

WEF
J J J JF
E J

EF

--

ECHARGING SYSTEMF

K
(transmission ratio)
K

WEF
J J JWF
E
E J JWF

EAlternator CoolingF
(radiation)
(conduction)
K

K
K
W
(internally ventilated alternators) J
(externally cooled alternators) J
(Internally Ventilated Alternators) J
K
FEF
KE

--

ECHARGING SYSTEMF

(claw-pole alternators)
K(salient-pole alternators)

K

WEF
W WF
W
E

F(claw-pole alternators)
K E


K
F(salient-pole alternators)
K E
KEF

K

K

(Externally Cooled Alternators) J
E F

--

ECHARGING SYSTEMF

K

K(convection)
K
K
(Diodes Cooling) J

K

K

(Water-cooled Alternators) J
FK
E
K

F K
KE
K

ETypes of AlternatorsF
W
K J
K J
K J
K J
KW J

--

ECHARGING SYSTEMF

K J
K J

K
K

K

K

W
W J
E F
K
K W J
F W J
K E
KW J
W J
K J
W
J
K(diode trio)
K W J

E
FE
FE
FK

K
--

ECHARGING SYSTEMF

F
WE FE
EF J
J
EXF J

W

J
(Claw-pole Alternators with Collector Rings)

J
(Salient-pole Alternators with Collector Rings)
E
F J
(Alternators with Winding less rotor (without collector rings))

J
(Claw-pole Alternators with Collector Rings)

K K
EF

K

K
K
EF N1 K1G1
EFT1
K


EFK
KK

--

ECHARGING SYSTEMF

WEF
J J J J JF

J
E J
J

WEF

J
(Salient-pole Alternators with Collector Rings)
EF

EF
E F K
K

--

ECHARGING SYSTEMF

K



K

(T2)
WEF
J J J J
JF

J J J J J
J

J J J

J
E J J J J

(T2, U2)
WEF

F

--

ECHARGING SYSTEMF

KE
F
(B+, B-)KE
K
KEF(T2)EFEF

(U2)
F
K E


K

E F J
(Alternators with Winding less rotor (without collector rings))
K(Brushless Alternators)? ?

K(worm-gear transmission)

K

KEF(N3)EF

(N3) WEF

--

ECHARGING SYSTEMF

J J J JF

J J J J
J
E J J










KEF

K

K
KK

K

--

ECHARGING SYSTEMF

(N3) WWEF

W

J J JF
E J

--

ECHARGING SYSTEMF

EAlternators Characteristic CurvesF

K
K
EF
K
(n)(I)(P)
KEF
K
K K

WEF
N1

(Current Characteristic Curve (I))( I ) J
(Minimum speed)Wno
ELFEnoF
K K

--

ECHARGING SYSTEMF

(Speed when engine idling) WnL

(Current when engine idling)nL WIL
KnL
EILF KEF
KEF
K {{EILF
(Speed at 2/3 rated current)LWN2/3
LKEZ
F
F K(IN)
KE
(n2/3)(nL)
K(2/3IN)(IL)
(Speed at rated current)WnN
(Rated current)WIN
K(IN) (nN)
(IN)
K
(Maximum speed)Wnmax
(Maximum current)WImax
KEnmaxF EImaxF

LK
K

(Characteristic Curve of Power Input (P))( P ) J
EF
KEF

--

ECHARGING SYSTEMF

K

(Explanation of Alternator Type-Code) EF J
K
F EF
EF E
KE
F EF
K

WWEF
W

WEF
FE FEFWN
E
W W1

W

--

ECHARGING SYSTEMF

W
E
F W
WWEF
WEFERF
WEFELF
WEFERLF
W28 V
W55 A
ELFLEFW25

--

ECHARGING SYSTEMF

WEF



EFEF
KEF
EF
LFL
KE

--

ECHARGING SYSTEMF

EMajor Differences between DC & AC GeneratorsF

K
K
EF
K

EF EF
EF F
EF E
F F

E E

F
E











--

ECHARGING SYSTEMF

EF
WEF

EF
KEF

(I)WEF
(n)
E J JF


K

K
K


ECurrent Calculation and Determining Correct AlternatorF
F
WE

--

ECHARGING SYSTEMF

J
K(Pw1)
J
K(Pw2)
EFEF J
Pw = Pw1 + Pw2K(Pw)
J
K(Pw)(IN)
(IN) J
K


(IL)
W


(Pw1) J
K(Iw1)(Pw1)
F{(Iw1) J
K(I1)(Pw1)E
(nL) (IL) J
KEIL = 2/3 INF
(IL I1) J
K

--

ECHARGING SYSTEMF

K1-14 V 55 A 20 W
K
KE F
EF J

WEF EZF WEF EZF





EF J

WEF WEF
{
{
{
{ {
{ {
{
{ {

EF EF J
Pw (W)


IN (A)

--

ECHARGING SYSTEMF

W
Pw1 = 350 (W)WEF J
Pw2 = 134 (W)WEF J
Pw = Pw1 + Pw2 = 350 + 134 = 484 (W)W J
IN = 55 (A)WEF J
W J
Iw1 = Pw1/14 = 350/14 = 25 (A)
W(Pw1) J
I1 = 1.3 x Iw1 = 1.3 x 25 = 33 (A)
IL = 2/3 IN = 2/3 x 55 = 36 (A)WEF J
IL > I1 J
F
KEL
E F

K
K

WEF

--

ECHARGING SYSTEMF

(Alternator Accessories)
(Alternator Vacuum Pump) EF J
(vane pump) EF
KEF
EF EF
K
E F
(throttle valve)
K

WEF


( Alternator Capacitors) J
EF
K

EAlternators AdvantagesF

K
K

--

ECHARGING SYSTEMF

W
EF J
J
J
K
K J
E F
J
K

K
K J
K J
K J
K J

--

ECHARGING SYSTEMF

W
(VOLTAGE REGULATORS)

EVoltage Regulators FunctionF

K

K

K
W

K

K
K
(Voltage Regulator)
KEF

WEF

EF
K


--

ECHARGING SYSTEMF

W
J
KEF
K J
K J
K J

EVoltage Regulation and Over-voltage ProtectionF
(Voltage Regulation) J

K
FKEF
E F E
K K
K

K

K

EF
EFK
KEF
E{{FEF
KEF{{

K(sensing voltage)??K

--

ECHARGING SYSTEMF

WEF


K E F
K(trickle charge)



K

K

ETemperature CompensationF J

K
K
K
EF
??K(temperature-sensitive resistor)EF
K(thermistor)

--

ECHARGING SYSTEMF

K
EF

K

EField CircuitsF J

WK
W(Field B-circuit)A J
K
KEF (B+)

BWAWWEF

W(Field A-circuit)B J
KEF K
K(B)
W(isolated field circuit) J
K(B+)
E
F
KEF(B+)

--

ECHARGING SYSTEMF

WEF
WWF
EB+

EOver-voltage ProtectionF J

K
EF
K

WEF


F
KE
K
K
F
E
K
--

ECHARGING SYSTEMF

F
KE
F
(zener diode ZD)KE
K(decay diode)

KEF
KEF(B+)
K(Iz)

WEF
J JFW EFWF
EE J J

EVoltage Regulators TypesF
(electromechanical regulators)
K Eelectromagnetic F
(transistorized/electronic regulators)L

K
(ECM)
K(computer-controlled)

--

ECHARGING SYSTEMF

FKEF
KE
K(ON-OFF cycle)

WEF

K
K(OFF)(ON)
K(OFF)(ON)
KEFE F

WEF
EWWF

(temperature compensation)
K
K

--

ECHARGING SYSTEMF

W
EF J
(Electromechanical or electromagnetic Voltage Regulators)
L J
(Transistorized/Electronic Voltage Regulators)

F J
(Engine Computer Control System) KE
EF J
(Electromechanical (electromagnetic) Voltage Regulators)
???
?
EF?
KEF

K

EFWEF
WE FWF
E F

J J

E
F
(current Regulator)(cutout relay) W

K(voltage regulator)
K
--

ECHARGING SYSTEMF

K

K
E F
K
K
(regulating resistance)EF
K EF

K

??
?
?
EF(single-unit electromagnetic vibrating-type regulators)

EFWEF
J J J JFWF
JFWEG J J
J J J
EE J
--

ECHARGING SYSTEMF

J J
F
KE

KEF
E
F
KEF
EF
K
K

WEF
WEFWF
E

E F
WEF
J
K
K

--

ECHARGING SYSTEMF

J
EF
KEF(voltage Regulator)
J
KL
J
(resistor) L
KL
(regulator armature)
K
J

K
J
K
KL

(Transistorized/Electronic Voltage Regulators)L J

(electronic voltage regulators)(transistorized voltage regulators)
Eintegrated circuit voltage regulators JF
K

K
K

--

ECHARGING SYSTEMF

(diodes)(integrated circuits)(power transistors)
K(solid state parts)

F K
KE
KEF

WEF

WEF
J J J JF
J J J J
E J

--

ECHARGING SYSTEMF

(on/off)L
EF
K

K
K
F EF
F E
(break-down
KE
Fpoint)
KE

KK

WEF
EWWF

F(regulator)
FEdiode trio JF E
K EFKE
--

ECHARGING SYSTEMF

EFWTR1
EFWTR2
EFWTR3
EFWC1
WD1
WD2
(thermistor)WR2
WR1, R3, R4, R5

WEF

(diode trio)(stator)
(indicator light)
K(R3)
(stator)
(D1)(R3)
(off)(TR1, TR3)(on)(TR2)
K(TR1)
(D1)(R3)
(TR1, TR3)(off)(TR2)
K(on)
K
(R4)(R3) (C1)
K(TR1)
(D2)(TR1)
--

ECHARGING SYSTEMF

K(off) (TR1)
K(R2)(thermistor)

EF J
(Computer-Controlled Voltage Regulation or Engine Computer Control System)
(ECUs)
K
F(electronic control units (ECUs))
Eengine computer J
E F
K
(logic module)
KEF(power module)

WEF

K (the duty cycle)? ?
--

ECHARGING SYSTEMF

K
KEF

Eon-time/off-timeLFWEF


E FK
K

K(on-time)

K
W
K J
K J
(magnetic drag) J
K(horsepower)

J
FEF
EFE

K

--

ECHARGING SYSTEMF

WEF



EHybrid RegulatorsF J


(hybrid techniques)

EFEF
K(film techniques)(ceramic plate)


KEF
F

(control stage) KE
(integrated circuit (IC))K(power stage)
F
E
--

ECHARGING SYSTEMF

KEF K

JEF JF WWEF
WE J J J
E J J JF

EF
K
EFK
E FK
K

K

K

--

ECHARGING SYSTEMF

KE F
K
F
E
K

--

ECHARGING SYSTEMF

W
ECharging System Maintenance and TestingF

K
K
K

(Charging System Inspection and Maintenance)

KK
K

K

W
J
K J
K J
J
K
J
K
J
K
K J
J
KE F

--

ECHARGING SYSTEMF

E F J
KEF
K J
K J

(Charging System Testing)

EFK
W K
F(Area Tests) J
KEFE
F(Bench Tests) J
KE

WEF
J JF

JEF J
J
E
--

ECHARGING SYSTEMF

ECharging-system Area TestsF J

(Testing the Drive Belt Tension) J J

EFK
E FK
K

WWWEF

EF
KK

WEF

--

ECHARGING SYSTEMF

(Charging-system Output Test) J J

K
W
J
KEF
K J
KL J
J
K
K J
K(off) J
K J

WEF

KEF

--

ECHARGING SYSTEMF

K

K
K

(Full-field Test) J J

FK

E
K(regulator by-pass test)??K

(test hole)K
KEF

WEF

EF

W
KEF J

--

ECHARGING SYSTEMF

J
K
EF J
K(off) J
K J
K
K

(Oscilloscope Checks)EF J J
EFKEF
K

K
F
K KE

EF WEF
WC WB WAF

EWD

--

ECHARGING SYSTEMF

(Alternator Bench Tests) J

K
K
K
K
K

(Check Brushes) J J
F
KKE
K

(Rotor Tests) J J
(open circuit)
K (test lamp)
K

EFWWEF
EFW

F(short to ground circuit)
--

ECHARGING SYSTEMF

E
K
K
(ohmmeter)
KKEF

(Stator Tests) J J
(open circuit)
KEF
KEF
(short to ground circuit)
E F
KK

K KEF

EFWWEF
EFW




--

ECHARGING SYSTEMF

(Diodes Tests) J J

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ECHARGING SYSTEMF

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ECHARGING SYSTEMF

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ECHARGING SYSTEMF

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ECHARGING SYSTEMF

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ECHARGING SYSTEMF

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ECHARGING SYSTEMF

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--

ECHARGING SYSTEMF

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--

ECHARGING SYSTEMF

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--

ECHARGING SYSTEMF

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--

ECHARGING SYSTEMF

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--

ECHARGING SYSTEMF

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--