ENGINEERING TECHNOLOGY

CHARGING SYSTEM
ETA211TC3

Eng. V. Madhushan
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Principle functions of a charging system

The charging system must meet the following criteria (when the engine is running).

• Supply the current demands made by all loads.

• Supply whatever charge current the battery demands.
• Operate at idle speed.
• Supply constant voltage under all conditions.
• Have an efficient power-to-weight ratio.
• Be reliable, quiet, and have resistance to contamination.
• Require low maintenance.
• Provide an indication of correct operation.

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 What is the main component of the charging system???

Alternator
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 Typical power requirements of some common vehicle electrical components

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 Charging system principles

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 CHARGING CIRCUIT
The charging system performs several functions, which are as follows:

• It recharges the battery after engine cranking or after the use of electrical accessories with the engine
turned off.
• It supplies all the electricity for the vehicle when the engine is running. It must change output to
meet different electrical loads.

• It provides a voltage output that is slightly higher than battery voltage.

Atypical charging circuit consists of the following:

• BATTERY-provides current to energize or excite the alternator and assists in stabilizing initial
alternator output.

• ALTERNATOR or GENERATOR- uses mechanical (engine) power to produce electricity.

• ALTERNATOR BELT- links the engine crankshaft pulley with alternator/ generator pulley to
drive the alternator/ generator.

• VOLTAGE REGULATOR- ammeter, voltmeter, or warning light to inform the operator of charging
system
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condition.
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Parts of the charging system

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 Why not “DC Alternators”???

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 AC Generator/Alternator

Alternator is an ACgenerator-Electromagnet passes across wire to induce

voltage

• Stator: stationary conductor

• Rotor: rotating electromagnetic field

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Stator Windings

Three sets of windings wrapped around slots in laminated round iron frame
(i.e., core), Each winding has two leads:
• one for current to enter and one to exit

Two types of Winding

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 Types of Winding cont…

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 Internal Alternator circuit

• Figure shows the full circuit of an alternator using an

eight-diode main rectifier and three field diodes.

• The warning light in an alternator circuit, in addition to

its function of warning of charging faults, also acts to
supply the initial excitation to the field windings.

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 Why is that Regulation of output voltage is important?

• To prevent the vehicle battery from being overcharged the regulated system voltage
should be kept below the gassing voltage of the lead-acid battery.

• Controls current passing through windings of electromagnetic

field in the rotor
 Determines amount of current produced in stator
 Increases current output when charging system voltage is
low
• Electronic voltage regulators
 No moving parts or contacts: very reliable
 Zener diode conducts electricity when a certain voltage is
reached
Figure. Action of the voltage regulator
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Computer voltage regulation/pulse

• Voltage regulation on late-model vehicles is done by the on-board computer, or powertrain

control module

• Electronic voltage regulation: can cycle 10-7,000 times per second

• Pulse width modulation: turning alternator on and off rapidly

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Alternator circuit (Japanese)

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High-Voltage Charging Systems

Important dates and concepts

1970: automobile required about 500 watts

2008: vehicle requires about 4,000 watts

2020: BASsystems will be included on all internal combustion engine vehicles

• BASsystems use 42-volt electrical systems with a 36-volt battery pack
• BASmotor/generator: larger than conventional AC generator

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The BAS(Belt Alternator Starter)-hybrid consists of five major components:

1. An electric motor / generator. AC current from the motor / generator is converted to DC current to
charge the batteries, and vice versa.

2. A coolant-cooled power electronics that controls the motor / generator and provides 12 volts to the
vehicle’s conventional battery.

3. Anickel metal hydride battery pack capable of 10 kW of power.

4. Aseparate engine-control module with Hybrid Supervisory Software to manage both the gas engine
and hybrid system.

5. Adifferent engine accessory drive with a dual tensioner assembly and aramid cord belt. This belt
transfers torque to the gas engine from the electric motor for starting and acceleration, and torque
from the engine to the motor to generate electricity.
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 Diagnosing charging system faults

As with all systems, the six stages of fault-finding should be followed.

1. Verify the fault.

2. Collect further information.
3. Evaluate the evidence.
4. Carry out further tests in a logical sequence.
5. Rectify the problem.
6. Check all systems

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 Testing procedure

1. Hand and eye checks (drive belt and other obvious faults) – belt at correct tension, all
connections clean and tight.

2. Check battery (see previous lecture slides) – must be 70% charged.

3. Measure supply voltages to alternator – battery volts.

4. Maximum output current (discharge battery slightly by leaving lights on for a few minutes,
leave lights on and start engine) – ammeter should read within about 10% of rated maximum
output.

5. Regulated voltage (ammeter reading 10 Aor less) – 14.2 0.2V.

6. Circuit volt drop – 0.5 V maximum.

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Common symptoms and faults of a charging system malfunction

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 New developments in charging systems

What is the current issue???

The main problem to solve is that of producing high output at lower engine speeds

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 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 corrosion (machine is enclosed).
• Resistance to high ambient temperature (130 ° C).

Valeo have also developed an alternator with a ‘self-start’ regulator.

This can be thought of as an independent power centre because the
warning light and other wires (not the main feed!) can be
eliminated.
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