5.

CHARGING SYSTEM

5.1 INTRODUCTION

In the charging system electronics devices such as diodes for rectification of

current in alternator zener diode and transistor for circuit opening and closing
in transistorised regulators are use. In this unit, the construction and function
of diodes and transistor, the purpose of the charging system, the component
parts of alternators, the generating principles of alternator, the charging
system service and repair are thoroughly discussed.

5.2 Semi conductors

Semi-conductors are elements that are neither good conductors nor good
insulators. Because of the atomic structure, the resistance of such materials
can be made to very widely with the application of small quantities of
impurities. Because of this characteristics, semi conducts are widely used in
the manufacturer of device as diodes and transistors.

The following elements are used in the manufacturer of semi-conductor

device such as diodes and transistors by doping process with germanium and
silicon.

No Element Valance Election

1 Antimony (S6) 5
2 Arsenic (AS) 5
3 Phosphorous (P) 5
4 Germanium (Ge) 4
5 Silicon (Si) 4
6 Aluminium (Ai) 3
7 Boron (B) 3
8 Gallium (Ga) 3
9 Indium (In) 3

N- type and p- type doping

The elements used for doping, generally have an electron valence of either
five or three, as a result, the doped smi conductors has either an excess or
shortage of electrons in the covalent bond structures. A semi- conductor with
electrons excess is the N- type while p- type has a shortage of electrons.

N- type semi- conductor

The doping elements Asnic, Antimony and Phosphorus have a valance

of five. For each outer most ring. In a covalent bond with Germanium (Ge) and
silicon (si) atoms having four valence electrons, each impurity atom provides
an extra electron, which is a free charge not needed for the covalent bond.

1
 Si Si Si

Si Si Si Free electron

Si Si Si

P- type semi- conductors

The dipping
Hole charge elements
Si Si Si
Aluminium, Born,
Gallium, and
Indium have a
valence of three
Si Al Si
electrons in the
outer most ring. In
a covalent bond
with germanium
Si Si Si (Ge) or silken (si)
atoms, there are
seven electrons instead of eight for each bond the one missing electron in
such a covalent bond can be considered as a free positive charge called hole
charge.

The Depletion region

P-N junction

P-Type P N N-Type
germanium germanium

When the P-N junction is formed, free electron diffuses across the junction to
combine with holes that are near the junction in the "P" section. At the same
time holes from the "P" section diffuse the junction to combine with free
electron's that are with in the N-Section near the junction. As a result of these
combinations the atoms near the junction of each section becomes ionised.
Since this action reduces the number of N-Sections and P-Section holes,
these are where the ionisation process takes place is called a depletion
region.

2
Potential Barrier

Because of the electron-hole combination within the depletion region, atoms

with in the "P" section gain electrons becomes negatively charged while
atoms within the N-section lose electrons and becomes positively charged.
This condition creates. A small voltage across the junction called potential
barrier because of polarity of the potential barrier, there is no further
significant diffusion of electrons from the N-Section and holes from the P-
Section.
The schematic symbol for diode

(+) (-)

Characteristics of diodes

When the N material is connected to the negative terminal of the battery, a

very high resistance is formed at the P-N junction. This state prevents a
current flow through the circuit.

But when the connection is reversed, they battery negative to the N-material
and the battery positive to the P-material this state will allow current to flow

Depletion
region

Negative - + Positive ion

ion
- +
- +

Potential
barrier

3
 C

Transistors

They are semi conductor devices containing

three semi-conductor regions each of which
has an external connection points. These B
terminals are called base(B), collector(C) and
emitter(E). PNP type transistor has one
negative region sandwiched between two
positive regions. NPN has one positive region
sandwiched between two negative regions
they are used for switching function. E
5.3 Purpose of the charging system
The charging system has two jobs. These are
a) To put back in to the battery the current used to start the engine
b) To handle the load of the lights, ignition, radio and other electrical
and electronic equipment's while the engine is running

The charging system includes the alternator regulator and battery with
connecting wires.

5.4 Generating principles of alternating current generator

An electrical generator is a machine that converts mechanical energy in to

electrical energy. This energy conversion is based on the principle of the
production of dynamically induced electromotive force. Whenever a conductor
cuts magnetic lines of force dynamically induced EMF is produced in it
according to faradays low of electromagnetic induction This EMF will cause a
current to flow if the conductor circuit is closed.

Hence the basic essential parts of an electrical generator are:-

a) A magnetic field
b) Conductors which can move so as cut the flux.
When the electricity by a coil is
supplied through slip rings and
brushes, the amount of current
flowing to the lamp will change and
at the same time so will direction of
flow.

As the coil rotates the current

generated on the first half of the turn
will be supplied from the brush on
side pass through the lamp then
retain to the brush on side B. On the
second half turn the current will be reversed. In this fashion, the alternating
current generator supplies the current generated by the coil in a magnetic
field.

4
The following figure illustrates
Rectification
The electrical components of an
automobile required direct current for
operation and battery needs direct
current for charging. The alternator
produces three phase alternating
current but the charging system of the
automobile can not use this electricity
unless it is converted to direct current.
There fore the alternating current is
rectified in to direct current by diodes
which are built in the alternator circuit.

Thus we can see current from each

coil to the diodes is constantly
changing direction in the three leads
so the direction of current from the
diodes does not charge but forms a
circuit with varying polarity.

5.5 The main components of the alternator and their functions

5
Rotor

The rotor is composed of two cores, a field coil slip rings and rotor shaft. The
field coil is wound in the same direction as rotation and each end of the coil is
Connected to a slip ring. The two cores are installed at each end of the coil so
as to enclose the field coil. Magnetic flux is produced as current flows through
the coil and one pole becomes the north pole and the other the south pole.
The slip rings are made of metal with a highly brush contacting surface and
they are insulated from the rotor shaft.

Stator

The stator is composed of stator coil, and is secured to the front and rear
ends of the frame. The stator core consists of thin layers of steel plating. The
inner side has slots in which there are three independent stator coils. The
stator core acts as a passage which allows the flux effectively cross to the
stator coil from the rotor core.

Diodes

Three positive diodes and three negative diodes are contained in their
respective diode holders. The current generated by the alternator is supplied
from the positive side diode holder so it is insulated from the end frames.

During rectification the diodes become hot so the diode holders act to radiate
this heat so the diode holders act to radiate this heat away and prevent the
diodes from overheating.

In addition, there are also brushes which supply current to the rotor for the
production of magnetic flux the bearings which allow the rotor to rotate
smoothly and a fun to cool the rotor, stator and diodes. All of these
components are hold by front and rear frames.

5.7 Regulators for alternators

Several types of alternator regulators that are mounted outside the alternator
have been used. The regulator limits alternator voltage by controlling the
amount of current flowing in the alternator field or the regulator reduces the
field current. This prevents excessive voltage.

A. One point type regulator

In this regulator a resistor (R) is connected in series with the field coil (F) of
the rotor. This resistance is by passed by the points while the engine is
running at low speed. Because the magnetic coil is weak and the points
remain closed when the voltage of the alternator is strong the points open and
current passed through the resistor and the field coil current is reduced and
the voltage of the alternator reduces and points close. In this manner the
voltage is stabilized by this type of regulator.

6
However, one point type regulator is not used very often in present day
automobiles be cause of the following disadvantage.

a) There is great fluctuation of voltage at low speed when the points

are opened and closed
b) A large resistance will cause more sparking when the points are
opens resulting shorter life of the points.

B. Two point type regulator

The characteristic of the two point type regulator is that it has both low speed
and high speed operating ranges.

At low speed, the moving point opens and closes the low speed point (P1) in
the same manner as the point make and break contact with the high speed
point and field current ceases to flow and the voltage out put of alternator
decrease as a result the moving point closes with P1 and this cycle is
repeated.

But the disadvantage of this type of regulator is the voltage drop due to the
hysterics effect when changing from the high speed side to low speed side.

Nevertheless. Compared to the one point type, the resistance can be made
smaller so there is less sparking so there is a longer life of the points.

C. Voltage Relay ( Charge lamp relay)

A Charging system employ a two element combination accurate voltage

regulation. This is because, the voltage regulator operates in accordance with
the voltage generated by the alternator. If there were no voltage relay, there
would occur a drop in voltage in the magnetic coil because the voltage is
applied to a long circuit via the ignition switch. A reduction of voltage would
cause a proportionate decrease in magnetic force of magnetic coil so the
moving points would not pulled sufficiently. As a result alternator voltage
would raise to high.

5.7.1 Characteristics of the regulators

For the point type regulators, there are various reasons why voltage
fluctuates. But the primary causes are due to its hysterics and temperature
characteristics.

A. The hysterics characteristics

The lowering of voltage when the moving point change from high speed side
to the low speed point called hysteretic effect causes to remain a residual
magnetism from the high speed operation in the coil core and continue to pull
the moving point for a short time. This phenomena cause to the alternator out
put to decline. There fore no attempt should be made to adjust the regulator

7
 when the voltage is dropping due to
this effect. A 12 volt system will drop
from 0.5 to a volt.

B. The temperature characteristics

The magnetic coil of the voltage regulator employs copper wiring. It

temperature of this wire rises, the resistance increased and there will be a
reduction of force (electromagnetic force) of the magnetic coil this results a
higher alternator out put voltage to prevent such arise in voltage, the regulator
utilizes either a resistor or bi-metal element for temperature compensation, but
some use both.

The resistor reduces the over all resistance in accordance with the
temperature fluctuation as a result
strong electromagnetic force is
developed and the contact point will be
pulled sufficiently.

The bi-metal element is used together

with a spring which supports the
moving point. The bi-metal element
reduces the spring tension as the
temperature rise. There fore the contact
point will be easily opened to prevent
the raise of alternator out put voltage.

5.7.2 Operation of a regulator with voltage relay

a. when the ignition switch is on engine stepped.

When the ignition switch is turned on field current from the battery flows to the
rotor and excites the rotor coil. At the same time, battery current also flows to
the charge warning lamp and the lamp comes on.

8
b. Engine operation- (low speed to middle)

9
After the engine is started and the rotor is turning. Voltage is generated in the
stator coil, and neutral voltage is applied to the voltage relay so the charge
warning lamp goes out. At the same time; out put voltage is acting on the
voltage regulator. Field current to the rotor is controlled in accordance with the
out put voltage acting on the voltage regulator. Thus depending on the
condition of point PL0, the field current either passes through or does not pass
through the resistor (R)

C. Engine operating (Middle speed to high speed)

As engine RPM increases, the voltage generated by the stator coil rises and
the pulling force of the magnetic coil becomes stronger with a stronger pulling
force, field current to the rotor will flow intermittently. In other words moving
point PL0 of the voltage regulator intermittently make contact with point PL 2.

10
5.8 IC Regulator

The integrated circuit regulator is compact and light weight and excellent
reliability due to its lack of mechanical points compared with the point type, it
has the following features.

Advantage

1. A narrower out put voltage range and little variation with time
2. Good resistance to vibration and high durability due to lack of
moving parts
3. Voltage out put becomes lower as its temperature rises, hence
proper charging of the battery can be performed.
Disadvantage

Susceptible to unusually high voltage and temperatures.

Operating principles of IC regulator

As in the illustration show, when the out put voltage at terminal B is low, the
battery voltage is applied to the base of Tr 1 through resistor R and Tr1 turns on
at the same time, field current to the
rotor flows from B-rotor coil.

When the out put voltage at terminal

B is high a higher voltage is applied
to the zener diod (ZD) and when
this voltage reaches the zener
voltages, the zenerdiod becomes
conductive. Accordingly, as Tr 2 turns
on Tr1 turns off. This interrupts the
field current. Regulating the out put
voltage.

11
5.9 Alternator checks and services
Before disassembling the alternator, noise test certainly test, are performed to
help us when each components are inspected during the disassembling stage

Rotor
A. Rotor test
Check that three is continuity
between the slip rings if there is
no continuity , replace

B Inspect rotor for ground

Check for
continuity between
the slip ring & rotor.
If there is continuity
replace the rotor.

C Inspect slip rings

Check the
slip ring
diameter if
it is less
than the
minimum
limit,
replace
the rotor.

Stator;

12
 a) Inspect stator for open circuit there must be continuity between
coil leads if not replace stator
b) Test stator for ground
Check if there is no continuity between the coil leads and the stator core. If
there is continuity, replace the stator

Rectifiers

a)
Inspect
positive rectifiers
 Using ohmmeter connect the one test probe to each rectifier
terminal, and the other to positive
 Reverse the polarity of the probe
 Check that the other shows continuity and the other doesn't
 If continuity is not as specified replace the holder

b) Inspect negative rectifier- Using an ohmmeter connect the test

probe to each rectifier terminal and the other to the negative
terminal
 Reverse the polarity
 Check that one shows continuity and the other doesn't
 If it is not as specified replace the rectifier holder

5.10 Regulator checks and service

a) Point surface inspection for burning if damaged, replace the regulator

b) Inspect resistance between terminals

* Between IG and F
At rest 0
Pulled in refer the specified resistance it must be about 10
 Between L and E
At rest 0

Pulled in refer to the specification of the regulator

 Between B and E

At rest- Infinity

Pulled in refer the specification

 Between B and L
At rest infinity
Pulled in approximately O

13
  Between N and E

The resistance must be checked with the specification

Adjustment

a. Adjust the voltage regulator by bending the regulator adjusting

arm
b. Adjust the voltage rely by bending the relay adjusting arm

14