Charging System

Replaces electrical energy drawn from the battery by forcing electric

current back into it

When engine is running, the alternator provides electricity to

recharge the battery and operate other electrical devices

The voltage regulator controls system voltage

To summarize, the charging system must meet the following criteria

a. Supply the current demands made by all loads.
b. supply current to battery for charging
c. supply constant voltage at all condition
d. require low maintenance
 CHARGING SYSTEM
Major Parts

•Battery

•Alternator
                                              

•Regulator
 Generator/Alternator
An electrical Generator/alternator is a machine which converts
mechanical energy (or power) into electrical energy (or power).

Principle :
   It is based on the principle of production of dynamically induced e.m.f
(Electromotive Force). Whenever a conductor cuts magnetic flux,
dynamically induced e.m.f. is produced in it according to Faraday's Laws
of Electromagnetic Induction. This e.m.f. causes a current to flow if the
conductor circuit is closed.
  
42 V electrical layout used in vehicle
Armature Reaction
 Cont…

In a uniform external field a rotating armature loop has no induced emf when its orientation is perpendicular to the
external field. As a point of reference, the plane where there is no induced emf is termed the neutral plane (see Figure 1
above).

If there is a current in the armature wires of a generator, the current will have its own magnetic field (see Figure 2 above).
This field and the external field interact, causing the net field between the generator poles to not be uniform – this is
different to the previously described case of a simple generator. The result is that the neutral plane is no longer
perpendicular to the external field of the generator (see Figure 3 above). This is known as the armature reaction effect.

The armature reaction effect can be a problem if the brushes in a DC generator are placed along a neutral plane
perpendicular to the external field due to the generator's electromagnets. When a rotating armature loop is in this
orientation, it is not in the true neutral plane and so will still have some induced emf and current. This can lead to
considerable sparking between the brush and the armature wire. To avoid this problem the brushes need to be positioned to
align with the new neutral plane.
Third Brush Regulation
 cont….

As the name implies, the machine had three brushes in contact with

the commutator. One was earthed to the frame of the vehicle and another was
connected (through a reverse-current cut-out) to the live terminal of the vehicle's
battery. The third was connected to the field winding of the dynamo. The other end
of the field winding was connected to a switch which could be adjusted (by
inserting or removing resistance) to give "low" or "high" charge. This switch was
sometimes combined with the vehicle's light switch so that switching on the
headlights simultaneously put the dynamo in high charge mode.
 Cutout relay

Cutout Relay
Sometimes called the circuit breaker, this device is a magnetic "make-and-break" switch. It
connects the generator to the battery (and therefore the rest of the car) circuit when the
generator's voltage builds up to the desired value. It disconnects the generator when it slows
down or stops.
The relay has an iron core that is magnetized to pull down a hinged armature. When the
armature is pulled down a set of contact points closes and the circuit is completed. When the
magnetic field is broken (like when the generator slows down or stops) a spring pulls the
armature up, breaking the contact points.
Cont..
Voltage Regulator
Compensated Voltage regulator
Alternator
 Construction difference: Alternator Vs Generator

The only significant difference in physical construction between an AC

and DC generator is the rotor's electrical connections. In an AC generator,
they are made with slip rings. In a DC generator, it is made with a
commutator. Both of these are connected by carbon brushes that ride
along the slip rings or commutator as they spin. A slip ring is a
continuous ring of copper used as a connection point. A commutator is a
series of small copper segments arranged into a ring shape, each segment
being a different connection point than the one next to it. Otherwise, in
theory, the two are basically identical, at least physically. They are
operated rather differently. As far as a moving coil in an AC generator,
the only coil that moves is the field winding contained within the rotor. It
is supplied with a DC voltage (referred to as exciting the field, which
turns it into an electromagnet, which spins with the rotor. The magnetic
field it produces spins along with it. The movement of the magnetic field
across the stator windings (the non moving part of the generator) causes
an AC voltage to be induced in the stator windings.
 Alternator Vs Generator
1) Generator speed is limited to 9000 RPM whereas 20000
RPM in alternator
2) Alternator size is smaller and lighter
3) Alternator does not require much maintenance attention
because of the use of light slip ring brushes when
compare with DC generator having heavy brushes and
Commutator.
4) An alternator is simple and robust hence more reliable
5) Cutout relay is not required
6) At low RPM or idling suitable voltage can be acquired
where as not possible in Generator bcz of Cutout relay.
7) In alternator
Understand the A/C Generator
(Alternator)
Identify the following components
Rotor
Stator
Slip rings
Brushes
Diodes or Rectifier
Rotor, creates spinning magnetic field
Stator, creates alternating current
Slip Rings, allow field current into the rotor
Brushes, allow field current into rotor
 Alternator
•Provides power to the electrical components and accessories,
When the vehicle is running.
•Converts mechanical energy to electrical energy
(Driven by Crankshaft, with the help of a drive-belt)

•The out put of alternator is DC, but actually AC voltage is generated

and then converted to DC.
 Rectifier Circuit

Full Wave Rectifier, Single Phase.

Uses 4 diodes to rectify both the negative and positive sides of the AC cycle. Almost
all electronic appliances that use grid power have a Full Wave Rectifier, including
your PC.

Full Wave Rectifier, 3 Phase.

Uses 6 diodes to rectifier all 3 phases, both negative and positive sides of each phase.
As you can see by the DC output, its a very smooth output compared to a full or half
wave single phase rectifier.
The diode trio takes the 3 phase rectified voltage from the rectifier bridge
and and joins it back into one single phase and ready it for the voltage
regulator.
 Alternator
S senses battery voltage

IG ignition switch signal turns the

regulator on.

L grounds the warning lamp

B alternator out-put terminal

F regulator full-field bypass

 Charging Circuit

B is out-put and supplies current to the battery

IG is ignition input, it turns on the alternator/regulator assembly.

S is used by the regulator to monitor charging voltage at the battery.

L is the wire that regulator uses to ground the charge warning lamp.
 Alternator

                                                                                                                                                          

                   
 Alternator Contains

•A rotating field winding called the rotor.

•A stationary induction winding called the stator.
•A diode assembly called the rectifier bridge.
•A control device called the voltage regulator.
•Two internal fans to promote air circulation.
 Alternator Drive Pulley
•Alternator drive pulleys either bolt on or are pressed on the rotor shaft.

•Both 'V' and Multi-grove types are used.

•Note this alternator does not have an external fan as part of the pulley
assembly.
 Regulator
•Regulator is the brain of the alternator.

•It controls the alternator out-put (Typically 13V to 15V).

•It monitors both battery and stator voltages and depending on the measured
voltages, the regulator will adjust the amount of rotor field current to control
alternator output.

•Electronic voltage regulator introduces more resistance between the

rotor windings and battery to reduce the alternator out-put.

•Mounted internally Externally

 Diode Rectifier
•The Diode Rectifier Bridge is responsible for the conversion or rectification
of AC voltage to DC voltage.
•Six or eight diodes are used to rectify the AC stator voltage to DC voltage.
•Half of these diodes are use on the positive side and the other half are on
the negative side.(mounted on a heat-sink)
 Diode Rectifier
Forward Biased acts as a conductor (Current passes through)

Reverse Biased acts as an insulator (Current does not pass)

 Rotor

•The rotor field winding creates the magnetic field that induces voltage into
the stator.

•The rotor spins creating an alternating magnetic field, North, South,

North, South, etc.

•Each end of the rotor field winding is attached to a slip ring. Stationary
brushes connect the alternator to the rotor.

•The rotor assembly is supported by bearings.

 Stator

•The alternating magnetic field from the spinning rotor induces an alternating
voltage into the stator winding.

•The strength of the magnetic field and the speed of the rotor affect the amount of
voltage induced into the stator.
 Stator Design
DELTA Delta wound stators can be identified because they have only
three stator lead ends.

•Delta stators allow for higher current flow being

delivered at low RPM.

•The windings are in parallel

 Stator Design
Wye (Y) wound stator have three windings with a common neutral junction.

•Can be identified by 4 stator leads.

•Used in alternators that require high voltage output at low alternator speeds.

•Two windings are in series at any one time during charge output.
 Brushes

Two stationary carbon brushes ride on two

rotating slip rings. Bushes are either
soldered or bolted.
 Water-cooled alternators
Valeo have an interesting technique involving running
the engine coolant through the alternator. A 120–190 A
output range is available. Compared with conventional air-
cooled alternators the performance of these new machines
has been enhanced more particularly in the following areas:
• Improved efficiency (10–25%).
• Increased output at engine idle speed.
• Noise reduction (10–12 dB due to fan elimination).
•Resistance to high ambient temperature (130 ° C).
Modern Electronic charging circuit
Latest Technology
Smart charging system
 Diagnosing
Common Symptoms
•Dead Battery

•Overcharging battery

•Abnormal noise

•Indicator shows problem

 Diagnosing
Preliminary Check

•Belt – too loose will slip and too tight will kill the bearings (Should
deflect ½” with thumb pressure)

•Battery/Charging Fuse or fusible link.

•Dirty terminal/post.

•Loose connections or broken wires.

 Diagnosing
•PERCAUTIONS

•Disconnect Battery.

•Do not reverse polarity.

•Do not operate alternator with battery disconnected.

 Diagnosing
Charging System Test
•Charging System out put test: measures current and voltage output of
charging system under a load(Most Accurate test).

•Regulator Voltage Test: measure charging system voltage under low output,
low load condition.

•Regulator Voltage Test: connect full battery voltage to alternator field,

leaving regulator out of circuit(By-pass Regulator).

•Circuit Resistance Test: measure resistance in insulated and ground circuits

of system (locate wiring problem).
 Diagnosing
Checking Diodes:

•The meter should read

high resistance (.010Ώ) one way
and low resistance(.999Ώ) the other.
 Diagnosing
Stator check

•Check resistance between terminals (A,B,C) and ground to Terminals.

•If resistance is high (infinite) the stator is shorted.
 Rotor Test
Short-to-Ground Test
 Rotor Test
Open Circuit Test
 Rotor Test
Current Test