1/18/2010

MEEC – Sistemas Automóveis

Charging Systems

Joana Maria Marques Bessa Teixeira

Nº 1031072

10 de Janeiro de 2010 | 1

Summary
MEEC – Sistemas Automóveis

• Introduction
• Constitution of the Charging System
• Dynamo vs alternator
• Alternator
• Fault diagnosis of the Charging System
• Assembling and removal of the Charging System
• Troubleshooting in the Charging System
• Battery
• Future Perspectives

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Introduction

• Taking into account the number of electrical devices that

must exist in any car, no matter how small, implies the
existence of an electrical system that, at the same time,
enables you to store electricity and maintenance of energy.

• It is in this context that the alternator, the car component

that is mounted on engine, and when driven by belts and
pulleys, generates electricity to power all consumers and
charge the battery. For this, the alternator turns AC current,
into DC.

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Constitution of the Charging System

This system consists

basically of:

• Battery

• Alternator

• Drive Belt

• Voltage Regulator

• Starter relay

• Fuse protection

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Dynamo vs Alternator

• The older vehicles used the dynamo to generate direct

current

• The dynamo did not have efficiency at idle, which does not
occur in the alternator

• This generates a high charge power at lower engine speeds

It appears that the

alternator begins to
supply electric power
with a rotation
essentially lower

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Dynamo vs Alternator

• The alternator and generator, are devices that use the

principle of induction Electromagnetic

• The generation of a magnetic field may be made through:

o Permanent magnets;

o Electromagnets (inductive coil).

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Dynamo vs Alternator

• Regardless, electric power generators (which convert

mechanical energy in power) can have two constructive
types:

o The inductor is the stator and the armature is the rotor;

o The inductor is the rotor and the armature is the stator.

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Dynamo vs Alternator

The production of electricity using the alternator, particularly

when the inductor is the rotor and the armature is the stator,
instead of the dynamo, has several advantages:

• The alternator has less maintenance;

• The alternator has better cooling than the dynamo;

• For the same electrical power generated, the dynamo is

much more voluminous and heavy;

• The alternator has a better return than the dynamo;

• The alternator has a simpler construction.

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Dynamo vs Alternator

In the particular case of the charging system of cars with

combustion engines, the advantages over the alternator to
dynamo are even greater:

• The dynamo reaches its nominal voltage to a number of

rotations higher than alternator;

• In the alternator, the rotor can run at higher speeds, at the

order of 15000 rpm, a value which is almost twice as much
as possible to achieve with dynamo.

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Dynamo vs Alternator

• The car uses the three-phase alternator

• It should be noted that automotive alternator, is the name

given to all: GeneratorAC, rectifier and voltage regulator.

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Alternator

The alternator includes some

elements of the system startup:
• Rotor (shaft, bearings,
inductive coil, and two polar
rings);
• Brushes;
• Stator (three-phase windings,
core);
• Bridge rectifying (diode);
• Cooling fan;
• Voltage regulator.

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MEEC – Sistemas Automóveis

Alternator

In the following figure represents is how the various

components may be assembled:

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Alternator

Rotor
The rotor consists:

• Two polar cores (magnetic

poles North and South);

• A inductive coil (rotor field

windings);

• Two slip rings;

• Rotor shaft.

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Alternator

Stator
• The rotor is inserted inside the stator;

• The stator of a three-phase alternator has three

independent groups of windings

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Alternator

Rotor
• The three groups of windings are arranged alternately;

• In the following figure we can see the rotor. It can be seen

that the polar cores has six pairs of poles:

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Alternator

Stator
• We can see in the figure below how the coils of the three
windings stator are connected for an alternator with six pairs
of poles inductors and twelve rolls per winding:

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Alternator

Stator
• The connection of the three stator windings can be made in
Y or delta, most commonly the first case:

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Alternator

Bridge rectifying (diodes)

• The three-phase alternated current generated by the

alternator has to be converted into current
continuous;
• The system segments that serve to the dynamo can not be
used in the alternator, because here the armature does not
run (stationary), the solution is to use a
rectifier device - a diode bridge

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Alternator

Bridge rectifying (diodes)

1. Battery;
2. Excitation coil (G);
3. Stator Coil;
4. Diodes plate positive;
5. Diodes plate negative;
6. Additional diodes;
7. Excitation diodes;

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MEEC – Sistemas Automóveis

Alternator

Bridge rectifying (diodes)

• The correction (full wave) of a three-phase system requires

two diodes for each phase, resulting in a total of six diodes.
• At one point in time, only two diodes are driving - are those
connected to the outputs of the alternator that have the
greatest potential (positive and negative) in the same
instant of time.

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Alternator

Bridge rectifying (diodes)

• When they applied three strains (U1, U2 and U3) staggered

120, the behavior of diodes will be the following Figure :

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MEEC – Sistemas Automóveis

Alternator

Bridge rectifying (diodes)

The three-phase
voltage output is
converted into
direct current
slightly wavy

Correction of the
three-phase AC

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Alternator

Bridge rectifying (diodes)

• The direction of currents in stator coils can change of

direction, but the direction of current in the load (battery
and receiver) is always the same:

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Alternator

Bridge rectifying (diodes)

The direction of currents in stator coils change of direction,

the direction of current in the load (battery and receiver)
is always the same:

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Alternator

Pre-excitation current

• In general, the alternators are self-exciting, ie, the excitation

current is obtained on the machine, deviated from the
mainstream current;
• The field of residual magnetism of the rotor will produce the
tension only with a high rotation;
• So that, it is necessary the pre-excitation of the alternator
on the start engine. The most practical way is in the form of
current on the battery through the indicator load lamp.

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MEEC – Sistemas Automóveis

Alternator

Pre-excitation current

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Alternator

Load current circuit

• In the post "D-" from the

alternator, you get the
current to charge the
battery and feed the
consumer electric
vehicle.

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MEEC – Sistemas Automóveis

Alternator

Current excitation circuit

• The excitation current to

produce the magnetic
field is derived from the
stator winding and
rectified by three diodes
and three special
excitation power diodes
negative.

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Alternator

Voltage regulator

• The f.e.m. produced by a given alternator varies with the

speed of rotation the rotor and the excitation current of the
inductor;
• In the case of the automobile, the speed of the engine varies
greatly, from 600-900 rpm up to 6000-7000 rpm;
• In these conditions, the voltage obtained in the alternator
would vary, and may reach values in the order of
250 V, which can not happen.
• To resolve this problem it is used the voltage regulator.

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MEEC – Sistemas Automóveis

Alternator

Voltage regulator
Electromecanical regulator

Maximum excitation current

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Alternator

Voltage regulator
Electromecanical regulator

Excitation current intermediate

Excitation current zero

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MEEC – Sistemas Automóveis

Alternator

Voltage regulator
Electronical regulator – Advantages

• Can be mounted internally in the alternator, avoiding

additional wiring required by an external regulator;
• There are no moving parts, it can run up to 7000 switching
on/off per second.

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Alternator

Voltage regulator
Electronic regulator
• Once perceived electromechanical regulators, whose key
element is the relay (right), to realize the electronic is only to
be replaced by a transistor, left)

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Alternator

Voltage regulator
Electronic regulator

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Alternator

Description and design of Alternators

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Fault diagnosis of the Charging System

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Assembling and removal of the Charging System

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MEEC – Sistemas Automóveis

Assembling and removal of the Charging System

(Dis) Assembling the Alternator (from) on the Motor Thermal

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Assembling and removal of the Charging System

(Dis) Assembling the Alternator (from) on the Motor Thermal

Example of mounting the alternator on a longitudinal engine

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MEEC – Sistemas Automóveis

Assembling and removal of the Charging System

(Dis) Assembling the Alternator (from) on the Motor Thermal

Mounting the alternator in a combustion engine with an

emphasis on the points of attachment

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Assembling and removal of the Charging System

(Un) Installation of Brushes

The usual way to fix the set of brush holder

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MEEC – Sistemas Automóveis

Mounting and removal of the Charging System

(Un) Installation of Brushes

Standard models of setting brush holder

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Assembling and removal of the Charging System

(Dis) Assembly Pulley and Fan

Ways of fixing polley, for

loosening the nut central

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Assembling and removal of the Charging System

(Dis) Assembly Pulley and Fan

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Assembling and removal of the Charging System

(Dis) Assembly of the Rotor Group

Identification of screws at the

support side of the drive

Procedure to remove the cover

drive side

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MEEC – Sistemas Automóveis

Assembling and removal of the Charging System

(Dis) Assembly of the Rotor

Separation of the cover front
bracket of the alternator rotor

1. The roller
2. Rings
3. Rotor field windings
4. Finger poles

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Assembling and removal of the Charging System

Replacement of bearings of the Rotor

The extraction of the bearing
should be carried out with the
help of an extractor, as shown in
Figure.

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MEEC – Sistemas Automóveis

Assembling and removal of the Charging System

(Dis) Assembly of the Stator

Extraction of the screws

that ensure the connection
of the coils to diodes

Marking the stator while

disassembling to be no
doubt when assembly

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Assembling and removal of the Charging System

(Dis) Assembly the Bridge rectifying (diode)

Extraction of the platform

that supports the diodes

Representation of the
screws fixed to the platform
diodes and their insulating
parts

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Troubleshooting in the Charging System

MEEC – Sistemas Automóveis

Troubleshooting - Alternator

Check belt tension that

drives the alternator

Disconnect the earth cable

Battery

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MEEC – Sistemas Automóveis

Troubleshooting - Alternator

Check the terminals with the help of a voltmeter, apply one

end of the voltmeter to the mass and the other will
check each of the terminals in the plug

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Troubleshooting in the Charging System

MEEC – Sistemas Automóveis

Troubleshooting - Alternator

Check the generated Check the Voltage drop

current of the "positive side”"

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MEEC – Sistemas Automóveis

Troubleshooting - Alternator

Test on the regulator with the regulator not

incorporated

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Troubleshooting in the Charging System

MEEC – Sistemas Automóveis

Troubleshooting - Rotor

Checking the
continuity of the shunt
excitation

Checking the insulation

of the rotor with a
lamp of 15 watts with
110 volt power
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Troubleshooting in the Charging System

MEEC – Sistemas Automóveis

Troubleshooting – Stator Coils

Checking the
continuity of the stator
using an ohmmeter

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Troubleshooting in the Charging System

MEEC – Sistemas Automóveis

Troubleshooting – Bridge rectifying (diode)

Verification of the
positive diodes - a
sense of drive and
direction of cutting

Verification of negative
diodes - a sense of
drive and direction of
cutting

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Troubleshooting in the Charging System

MEEC – Sistemas Automóveis

Troubleshooting – Brushes

Checking the isolation of one of the brushes with an

ohmmeter.

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Battery
MEEC – Sistemas Automóveis

Funcions
• Provide energy to operate the starter motor;

• Addressing energy bulbs of car lights;

• Act as voltage stabilizer for the system load;

• Provide current when the power demand of the car exceeds

the capacity of the system load (alternator).

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Battery

MEEC – Sistemas Automóveis

Elements:

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Future Perspectives
MEEC – Sistemas Automóveis

Currently the electric cars are undergoing marked changes due

to various factors:
• Due to increased consumption with accessories
• The increasing number of electrical devices to perform
functions before driven directly by the engine,
• The incorporation of devices to reduce consumption and
assist the driver,
• The incorporation of new safety devices,
• The urgent need to reduce fuel consumption and emissions.

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Future Perspectives

MEEC – Sistemas Automóveis

Alterno-starter
• It is a new system known as alterno-starter that meets starter
and alternator in one piece
• The alterno-starter is an alternator that continues to act as a
generator of current but also acts as the starter. As receiving
information through a electronic sensor that is activated, the
rotor of the alternator turns and through transmission by
pulleys and current gear, drives the crankshaft.

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References

• Mário Alves, Manuel Lourenço, ”Automóvel – Sistema de

Carga 1ª Edição”, ISEP, 2009.

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