Automobile charging system

The purpose of the charging system is to maintain the charge in the vehicle’s battery, and to provide the
main source of electrical energy while the engine is running. The automobile charging system generates,
regulates and supplies the electrical energy for charging the battery. Main requirements of a charging
system, when the vehicle is running are:

1. To supply the current demands of all the loads.

2. To supply the current required for charging of battery under all conditions.
3. To supply constant voltage under all conditions.
4. Should have highest power to weight ratio.
5. Should be reliable and quite.
6. Should require least maintenance.

The charging system consists of a generator for converting mechanical energy from the engine into
electrical energy, a regulator to control the amount of electrical energy so produced, a relay to regulate
the flow of the charging current from generator to the battery relevant to the state of charge of the
battery and an ammeter or indicating lamp to indicate whether the system is operation or not.

Purpose and functions of charging system:

The battery itself is charged by a generator driven by the engine (known as alternator) and as long as the
engine is running there will be a current flowing through the battery. The regulator is used to regulate
the output voltage (to the battery) to the 14.4 volt DC that is required.

The purpose of charging system is to maintain the charge in the battery of the vehicle. It consists of
alternator, regulator, rectifier setup which provides the main source of electrical energy while the
engine is running.

Working of alternator:

Compared to generator, an alternator only produces alternating current. Generally the magnetic field is
rotating inside the stator of an alternator whereas, in case of a generator, the magnetic field is
stationary or fixed where the armature winding spins. In principle, any AC electrical generator can be
called an alternator, but usually the term refers to small rotating machines driven by automotive and
other internal combustion engines.

As shown in the figure, an electromagnet (rotor) is mounted on a shaft and is supplied current for its
energisation from a battery through the slip rings and brushes. The rotator is turned by a belt and pulley
by the engine. In series with the stator winding are diodes as shown in the figure which are further
connected to outside electric circuit.

When the electromagnet is rotated, the magnetic lines of force cut the stationary stator loop to produce
an induced current. However, as after every half revolution, the magnet reverses its polarities, the
current produced in the stator alternates in sign in a revolution. To convert this alternating current into

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the direct current, diodes are employed, which allows the current to pass through them only in one
direction. Thus it is the direct current which is fed to the electrical circuits inside an automobile.

The rectified voltage the goes to charge the battery. There is a voltage regulator connected to the
upcoming rectified DC voltage. The voltage regulator is connected to the battery and also to the rotor.
Current is passed to the rotor through voltage regulator. Also the voltage regulator regulates the voltage
passing from the rectifier to the battery.

Whenever the vehicle is slow, the battery sends more power to the rotor so that the electromagnet
becomes more powerful to produce enough (14.4 volt) DC current. And when the speed of vehicle
increases, the voltage regulator passes less current to the rotor so that the output voltage coming from
the stator coil adjusts to same 14.4 volt DC. In this way the battery always receives a constant charging
voltage of 14.4 volt DC. This is the working of alternator (charging system).

(Note: Combination of diodes form a rectifier which converts AC to DC)

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 Functions of different parts of alternator:

1. Regulator: The voltage regulator controls the amount of power distributed from the alternator
to the battery in order to control the charging process. Regulators are designed with different
functions and work depending on their specification.
2. Rectifier: The rectifier is used to convert current from alternating current (AC) to direct current
(DC) during the charging process.
3. Rotor: The rotor is the spinning mass inside the alternator that rotates via the pulley and drive
belt system. The rotor acts as a spinning electromagnet.
4. Slip Rings: The Slip rings are used as a means of providing direct current and power to the rotor.
5. Slip Ring End Bearing: The bearings are designed to support the rotation of the rotor shaft.
6. Stator: The stator consists of several coils of wire wound through an iron ring. The stator sits
outside the rotor, when a magnetic field is created the electrical current is made.
7. Drive End Bearing: The bearings are designed to support the rotation of the rotor shaft.
8. Pulley: The pulley is connected to the rotor shaft and the drive belt system. Rotation created by
the engine the drive belt system turns the pulley beginning the charging process.

Importance and functions of regulator:

The voltage regulator controls the alternator’s power output. It regulates the charging voltage that the
alternator produces. It keeps the voltage between 13.5 and 14.5 volts to protect the electrical parts in
the vehicle.

The purpose of a voltage regulator is to keep the voltage in a circuit relatively close to a desired value.
Voltage regulators are one of the most common electronic components, since a power supply
frequently produces raw current that would otherwise damage one of the components in the circuit.

Fault and remedies:

S.N. Faults Causes Remedies

1. Battery is not charging while a. Too loose alternator drive a. Adjust per specification
engine is running belt
b. Worn out slip rings b. Install new
c. Open rectifier c. Install new if necessary

2. The alternator continues to
charge at high rate even after
battery attains full charge
3. Noisy alternator while running
a. Voltage regulator set too a. Reset the regulator
high
b. Stuck regulator contacts b. Install new regulator
c. Poor regulator grounding c. Correct ground connection
a. Loose mounting a. Tight the mounting
b. Worn out bearings b. Replace the bearings

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