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Charging Systems
Basic Charging System Components
Typical components are:
 Alternator Drive Belt:
Drives alternator from
crankshaft.
 The Battery: Supplies
voltage to alternator.
 Charge Warning Lamp:
Displays charging system
information.
 The Alternator: converts
mechanical power to
electricity.
Engine off, battery supplies
electricity to systems.
Engine running, charging
system supplies
electricity to systems.
The alternator is driven
from the crankshaft pulley.
Its output voltage varies
between 13 and 15 volts.
This is sufficient to charge the battery.
Charging System Operation
Load
13 - 15 volts
Battery
alternator
The Alternator (External Side View)
Typical alternator
construction:
Drive
pulley Output
terminal
B+
Regulator,
rectifier
and brush
cover
End frame
cover
Mounting
ear
Drive frame
cover
Circulation
vents
Cooling
fan
 The rotor: Rotating
field winding.
The Alternator (Internal View)
Typical components are:
Voltage
regulator
Rectifier
assembly
Rotor
Stator
Drive
pulley
End
cover
Slip ring
end
housing
Retainer
nut
Casing retainer
bolts
 The stator:
Stationary induction
winding.
 Rectifier
assembly: Diode
rectifier bridge.
 Voltage regulator:
Regulates output
voltage.
 Cooling fans: Provide
air circulation.
Cooling fans
Field winding
Main
shaft
Slip
rings
Brushes
Iron, claw-
shaped, finger
pole pieces
Alternator Components - The Rotor
Typical rotor components:
 The field winding is
wound over an iron
core.
 The finger poles
surround the field
winding.
 The brushes
transfer voltage
to the slip rings.
 The rotor assembly is
supported at each end
by bearings.
 The field winding
is attached to the
slip rings.
Rotor Magnetic Field
When voltage is applied to the field winding, a magnetic field is
created.
Magnetic field strength = current flow + closeness of finger poles.
It saturates the finger poles, creating north and south poles.
As the rotor turns, alternating north and south magnetic fields are created.
Stator
windings
Curved flux
lines
Voltage in
North and
south poles
Alternator Components - The Stator
The stator has 3 sets of evenly spaced windings.
They are held within a
frame of soft iron
laminations.
The windings connect to
a diode rectifier bridge.
Stator
Enamel copper
wire windings
Soft iron
lamination
3 outputs
Output voltage depends
upon rotor speed and its
magnetic field strength.
The windings are interlaced
to produce AC voltages that
are 120° apart.
+
-
0
Single Phase Voltage Induction
Maximum voltage = when winding
is cut by maximum flux.
Single winding (stator).
When magnetic field direction
changes, induced voltage polarity is
reversed.
When magnet rotates, it
induces voltage in the winding.
Occurs when magnet is at
90° to winding.
Magnet (rotor).
Winding
Magnetic
field
Rotor
120°
0
180 360
The stator has 3 windings, that
are 120° apart.
The voltages produce a stable 3
phase output, ready for DC
conversion (rectification).
Three Phase Voltage Induction
As the magnet rotates, it induces
voltages in all 3 windings.
The windings are connected in either Star or Delta configurations.
Star Delta
Diodes allow current to flow in
only one direction.
Rectification
If 4 diodes are connected to
make a bridge, current can
flow during positive and
negative parts of the AC
voltage, producing a totally
positive (DC) output.
They conduct when a forward
voltage is applied to the anode.
In this case, the positive
part of an AC voltage.
Anode Cathode
+ -
Output
Diode
AC
voltage Battery
emf
+
-
Output
AC
voltage
D1
D4
D2
D3
Battery
emf
+
-
Converts 3 phase AC voltage
into DC voltage.
Alternator Components - The Rectifier Bridge
The bridge is constructed
using 6 diodes.
3 are used on the positive side of
the bridge and 3 are used on the
negative side.
The diodes are mounted on
a heat sink.
‘B’ terminal
Negative
diodes
Stator terminals
Positive
diodes
Rotor Field Excitation
The rotor requires voltage to produce a magnetic field.
Engine stopped, ignition
on, battery voltage is
applied to rotor, via
charge warning lamp.
Lamp is on and current
flows through rotor
winding.
Engine running,
alternator speed increases,
voltage output also
increases.
Alternator voltage > battery voltage = lamp out, battery being charged
= alternator current flowing through rotor, via field diodes.
Alternator Components - Voltage Regulator
Rotor field winding voltage must be
regulated to maintain alternator output
at specified voltage level.
The voltage regulator
senses alternator output
and changes field winding
current.
Output voltage < specified, regulator increases field winding current,
output voltage increases.
Output voltage > specified, regulator decreases field winding current,
output voltage decreases.
Typical Voltage Regulator Circuit
Regulation voltage is set by voltage drop across R1, ZD and T1.
Battery voltage < 14.2V, ZD does not conduct, T1 off, T2 on, rotor current = max.
Alternator voltage >= 14.2V, ZD conducts, T1 on, T2 off, rotor current = 0.
Rapid switching of transistors provides a stable output voltage.
Regulating circuit
Rotor
Stator
Rectifier
Field diodes
Battery
Starter
solenoid
Charge warning
lamp and
ignition switch
Typical Alternator Circuit
A typical alternator circuit is shown below.
The regulator senses alternator voltage at the starter solenoid.
Open-Circuit Check
Measure the resistance
between the slip rings with
the ohmmeter. the resistance between
3.5 – 4.5Ω
Grounded Circuit Check
Check for resistance between
the slip ring and the core. The
rotor is defective if the
resistance is not infinite (∞).
ALTERNATOR ROTOR INSPECTION
ALTERNATOR STATOR INSPECTION
Continuity Between Coil Leads
Check for continuity between
the stator coil leads. The
stator is defective if no
continuity
Continuity Between Stator
Coil Leads and Core
Check for continuity between
the stator coil leads and the
core. The stator is defective if
continuity exists.

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Charging Systems - Copy.ppt

  • 2.
  • 3. Basic Charging System Components Typical components are:  Alternator Drive Belt: Drives alternator from crankshaft.  The Battery: Supplies voltage to alternator.  Charge Warning Lamp: Displays charging system information.  The Alternator: converts mechanical power to electricity.
  • 4. Engine off, battery supplies electricity to systems. Engine running, charging system supplies electricity to systems. The alternator is driven from the crankshaft pulley. Its output voltage varies between 13 and 15 volts. This is sufficient to charge the battery. Charging System Operation Load 13 - 15 volts Battery alternator
  • 5. The Alternator (External Side View) Typical alternator construction: Drive pulley Output terminal B+ Regulator, rectifier and brush cover End frame cover Mounting ear Drive frame cover Circulation vents Cooling fan
  • 6.  The rotor: Rotating field winding. The Alternator (Internal View) Typical components are: Voltage regulator Rectifier assembly Rotor Stator Drive pulley End cover Slip ring end housing Retainer nut Casing retainer bolts  The stator: Stationary induction winding.  Rectifier assembly: Diode rectifier bridge.  Voltage regulator: Regulates output voltage.  Cooling fans: Provide air circulation. Cooling fans
  • 7. Field winding Main shaft Slip rings Brushes Iron, claw- shaped, finger pole pieces Alternator Components - The Rotor Typical rotor components:  The field winding is wound over an iron core.  The finger poles surround the field winding.  The brushes transfer voltage to the slip rings.  The rotor assembly is supported at each end by bearings.  The field winding is attached to the slip rings.
  • 8. Rotor Magnetic Field When voltage is applied to the field winding, a magnetic field is created. Magnetic field strength = current flow + closeness of finger poles. It saturates the finger poles, creating north and south poles. As the rotor turns, alternating north and south magnetic fields are created. Stator windings Curved flux lines Voltage in North and south poles
  • 9. Alternator Components - The Stator The stator has 3 sets of evenly spaced windings. They are held within a frame of soft iron laminations. The windings connect to a diode rectifier bridge. Stator Enamel copper wire windings Soft iron lamination 3 outputs Output voltage depends upon rotor speed and its magnetic field strength. The windings are interlaced to produce AC voltages that are 120° apart.
  • 10. + - 0 Single Phase Voltage Induction Maximum voltage = when winding is cut by maximum flux. Single winding (stator). When magnetic field direction changes, induced voltage polarity is reversed. When magnet rotates, it induces voltage in the winding. Occurs when magnet is at 90° to winding. Magnet (rotor). Winding Magnetic field Rotor
  • 11. 120° 0 180 360 The stator has 3 windings, that are 120° apart. The voltages produce a stable 3 phase output, ready for DC conversion (rectification). Three Phase Voltage Induction As the magnet rotates, it induces voltages in all 3 windings. The windings are connected in either Star or Delta configurations. Star Delta
  • 12. Diodes allow current to flow in only one direction. Rectification If 4 diodes are connected to make a bridge, current can flow during positive and negative parts of the AC voltage, producing a totally positive (DC) output. They conduct when a forward voltage is applied to the anode. In this case, the positive part of an AC voltage. Anode Cathode + - Output Diode AC voltage Battery emf + - Output AC voltage D1 D4 D2 D3 Battery emf + -
  • 13. Converts 3 phase AC voltage into DC voltage. Alternator Components - The Rectifier Bridge The bridge is constructed using 6 diodes. 3 are used on the positive side of the bridge and 3 are used on the negative side. The diodes are mounted on a heat sink. ‘B’ terminal Negative diodes Stator terminals Positive diodes
  • 14. Rotor Field Excitation The rotor requires voltage to produce a magnetic field. Engine stopped, ignition on, battery voltage is applied to rotor, via charge warning lamp. Lamp is on and current flows through rotor winding. Engine running, alternator speed increases, voltage output also increases. Alternator voltage > battery voltage = lamp out, battery being charged = alternator current flowing through rotor, via field diodes.
  • 15. Alternator Components - Voltage Regulator Rotor field winding voltage must be regulated to maintain alternator output at specified voltage level. The voltage regulator senses alternator output and changes field winding current. Output voltage < specified, regulator increases field winding current, output voltage increases. Output voltage > specified, regulator decreases field winding current, output voltage decreases.
  • 16. Typical Voltage Regulator Circuit Regulation voltage is set by voltage drop across R1, ZD and T1. Battery voltage < 14.2V, ZD does not conduct, T1 off, T2 on, rotor current = max. Alternator voltage >= 14.2V, ZD conducts, T1 on, T2 off, rotor current = 0. Rapid switching of transistors provides a stable output voltage.
  • 17. Regulating circuit Rotor Stator Rectifier Field diodes Battery Starter solenoid Charge warning lamp and ignition switch Typical Alternator Circuit A typical alternator circuit is shown below. The regulator senses alternator voltage at the starter solenoid.
  • 18. Open-Circuit Check Measure the resistance between the slip rings with the ohmmeter. the resistance between 3.5 – 4.5Ω Grounded Circuit Check Check for resistance between the slip ring and the core. The rotor is defective if the resistance is not infinite (∞). ALTERNATOR ROTOR INSPECTION
  • 19. ALTERNATOR STATOR INSPECTION Continuity Between Coil Leads Check for continuity between the stator coil leads. The stator is defective if no continuity Continuity Between Stator Coil Leads and Core Check for continuity between the stator coil leads and the core. The stator is defective if continuity exists.