2 - Charging System

Charging systems
The ‘current’ demands made by modern vehicles

are considerably increasing.
The charging system must be able to meet these

demands under all operating conditions and
still ‘fast charge’ the battery.
The alternator generates AC but must produce DC

at its output terminal as only DC can be used to
charge the battery and run electronic circuits.
1
Automotive electrical and electronic systems, charging system
Charging system must meet the following criteria
• Supply the current demands made by all loads.
• Supply whatever charge current the battery demands.
• Operate sufficiently even 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.
2
Alternator basic operating principles
• An alternator, converts mechanical energy from the engine into electrical energy.
• The basic principle of an alternator is a magnet (the rotor) rotating inside
stationary loops of wire (the stator).
• Electromagnetic induction caused by the rotating magnet produces an
electromotive force in the stator windings.
• In order for the output of the alternator to charge the battery and run other vehicle
components, it must be converted from alternating current to direct current.
• The component most suitable for this task is the silicon diode.
• In order to full-wave rectify the output of a three-phase machine, six diodes are
needed.
• These are connected in the form of a bridge in a rectifier pack. Many rectifiers
now include two extra diodes that pick up extra power from a center connection
to the stator.
• A regulator, which controls rotor magnetic field strength, is used to control the
output voltage of an alternator as engine speed and current demand change.
3 Automotive electrical and

electronic systems, charging
Current demand
4
The list below summarizes the major subsystems (and loads) of the
automotive electrical/electronic content of a modern automobile in the
following categories:
 Engine management
 Multimedia and heating, ventilation, and air conditioning (HVAC)
 Body electronics
 Chassis electrification
 Lighting (exterior and interior)
 Future systems
system
Current loads
Vehicle electrical loads
three groups :
1. Continuous,
2. Prolonged,
3. Intermittent.
7
The sum of these loads
(with the factor applied):
180 + 260 + 170 =610W

(43A at 14V)
in addition to the
current required to
recharge the battery.
Automotive electrical and

8 electronic systems,
charging system
Charging system principle
When the alternator voltage
is less than the battery, the
direction of current flow is
from the battery to the
vehicle loads. The alternator
diodes prevent current
flowing into the alternator.
When the alternator output
is greater than the battery
voltage, current will flow
from the alternator to the
vehicle loads and the
battery.
9
Charging voltages
•Charging system voltage is set to value then there
can be no risk of overcharging the battery.
•This is known as the constant voltage charging
technique.
•The figure of 14.2 ± O.2V is the accepted charging
voltage for a 12 V system.
•Voltage drops in the charging circuit wiring must
be kept to a minimum.
•A voltage of the alternator may be slightly above
that supplied to the battery.
10
Generation of electricity
•Electromagnetic
induction caused by a
rotating magnet inside a
stationary loop or loops
of wire.
•In a practical alternator,

the rotating magnet is an
electromagnet that is
supplied via two slip
rings.
11
Alternator principle of operation
12
Stator and rotor
•Stator consists of three separate phases, each with a number of

windings.
•The windings are mechanically spaced on a laminated core (to reduce
eddy currents),
•The number of windings must be matched to the number of poles on the
13 rotor. Automotive electrical and electronic systems, charging system
Rotor poles and inducing current
Each end of the rotor will become a

north or a south pole and so each
claw will be alternately north and
south (12 or 16 poles).
14
AC inducing in alternator
15
Delta and star windings of
stators
delta windings
star windings
The three-phase windings of the stator can be connected in two

ways:-
•star windings (series connection), produce a higher voltage
16 •delta windings, (parallel connection), produce a higher current.
The voltage and current in three-phase
stators:-
Star-wound stators: type of series circuit.
V  VP 3
The output voltage across any two
phases will be the vector sum of the
phase voltages. Current output will be
I  IP the same as the phase current.
A delta connection: type of parallel circuit.

V  VP The output voltage is the same as the
phase voltage but the output current is
I  IP 3 the vector sum of the phase currents.
where :V- output voltage; Vp- phase voltage;

I - output current; Ip- phase current.
17 Most vehicle alternators use the star (series) windings
Frequency of an alternator
Important if an AC tapping from the stator is used to run a vehicle
rev-counter:
Where:
f= frequency in Hz;
n=alternator speed in rev/min
p= number of pole pairs (a 12 claw rotor has 6 pole
pairs).
An alternator when the engine is at idle, will have a

speed of about 2000 rev./min. which, with a 12 claw
rotor will produce a frequency of:-
18 f = 6 X 2000/60 = 200 Hz.
Rectification of AC to DC
Alternating current (AC)
must be converted to direct
current (DC) by using silicon
diodes, to charge the battery
and run other vehicle
components.
The negative cycles are

blocked.
four-diode bridge rectifier

will block reverse flow up to
a pressure of about 400 V
it will still require a small

voltage pressure of about 0.6
V to conduct in the forward
19
direction. Automotive electrical and electronic systems, charging system
Three-phase rectification
In order to full-
wave rectify the
output of a three-
phase machine,
six diodes are
required:-
- three positive diodes.
- three negative diodes.
20
Auxiliary positive diods to
supply current to rotor
Auxiliary, field or
excitation diodes.
are often included in a
rectifier pack.
They used to:-

1) supply a small current
back to the field
windings in the rotor.
2)prevent reverse
current flow from the
battery to the alternator.
21
Conversion process from AC to
DC
22
23
Third harmonic
• When a star-wound stator is
used (which is more common
in alternators), the voltages at
the neutral point of the star is
in theory, 0 V.
• In practice, a potential voltage
develops at this point. This
potential (voltage) is known
as the third harmonic
• This due to slight
inaccuracies in the
construction of the stator and
rotor
• Its frequency is three times Third harmonic
the fundamental frequency of
the phase windings.
24
Extra diods to increase output
current
•By employing two
extra diodes, one
positive and one
negative connected to
the star point, the
energy can be
collected.
•This can increase the

power output of an
alternator by up to
15%.
25
Full circuit of an alternator using an eight-
diode main rectifier and three field diodes.
Auxiliary field
diodes supply the
initial excitation to
the field windings,
in addition to
operate the
warning light in an
alternator circuit,
to warn about any
faults in charging
system.
26
Circuit diagram for an alternator
and regulator

Regulation of alternators output voltage

Principle of regulatation
-The output of an alternator without regulation
would rise linearly in proportion with engine
speed.
-Alternator output is proportional to magnetic
field strength
-Magnetic field is proportional to the field
current.
-The regulator controls the field current in
order to regulate alternator output voltage.
30
Regulation of output voltage
Flow chart represents the regulator action
Output voltage
should be regulated:-
1) To prevent the
vehicle battery from
being over charged.
2) To supply
electronic systems
with accurate voltage
control.
31
Voltage regulator cycling the
rotor field current
Field current is
switched off as
output voltage
increases and then
back on again as
output voltage falls.
The whole switching

process only takes a
few milliseconds.

electronic systems,
charging system
Location of voltage regulator in
circuit
(a) Alternator circuits
supply a constant feed a b
to the field windings
regulator switches
from the excitation Field the supply side.
diodes and the winding
regulator switches the
earth side.
(b) The field windings regulator
is constantly earthed
and the regulator
switches the supply
side. regulator switches
the earth side
33
Simplified circuit of mechanical
regulator From the output
Regulators:- Of the alternator
1) Mechanical.
2) Electronic.
The mechanical type

uses a winding
connected across
the output of the
alternator.
The problem with Normally
closed
mechanical contacts
regulators is the
wear on the
contacts and other
moving parts
34
Electronic voltage regulator
The key to electronic
voltage regulation is the
Zener diode.
Zener diode can be

designed to maintain a
constant DC output
voltage across the load in
spite of variations in the
input voltage or changes
in the load current.
Zener diode can be

constructed to break
down and conduct in the
reverse direction at a
precise level (400 V)
35
The Electronic (transistor) regulator’s
advantages
▶ Shorter switching times which permit closer control tolerances
▶ Maintenance-free (no wear)
▶ High switching currents
▶ Spark-free switching, which causes no radio interference
▶ Insensitive to shock, vibration, and climatic effects
▶ Temperature compensation
▶ Compact construction allows direct mounting on the alternator,
irrespective of alternator size.

Electronic regulators can be made to:-
1)Sense the battery voltage.
2)The alternator voltage.
3)Combination of the two.
Most systems in use at present tend to be alternator

sensed as this offers some protection against over-
voltage in the event of the alternator being driven
with the battery disconnected.
A second sensing system (Sense the battery voltage)

reads the actual voltage at the battery and signals
the alternator to increase its voltage output to
compensate for voltage drop, ensuring a constant 14
volts at the battery.
37
Voltage regulation during summer and winter conditions;-
When a battery is cold, the electrolyte resistance increases. This means a
higher voltage is needed to produce the correct recharging current.
Bosch produce compact alternator
with outstanding features:-
• 20-70% more power than
conventional units.
• 15-35% better power-to-weight ratio.
• Maximum speed up to 20000
rev./min.
• Twin interior cooling fans.
• Accuracy construction for reduced
noise.
• Versions available: 70, 90 and up to
170 A.
Enhancements made to the magnetic
circuit of the rotor and to the stator.
• The voltage drop across the main
power transistor reduced from 1.2V
to 0.6 V
electronic systems,
charging system
Water cooled alternators
Heavy duty alternators
equipped with water cooling
system sharing engine
cooling system, traditional
alternators cooling by air.
Water cooled alternater
has:-

Options for changes the power
supply of alternator
Worst alternator operating conditions(traffic jam and open parking in cold
nights).
Five options for Battery state of charge
improving the output of

power supply system
• Fitting a more powerful
alternator.
• Power management
system.
• Two-stage alternator
drive mechanism or
increased alternator
speed.
• Increased engine idle Remember, power supplied by an alternator
speed. is not free. For each watt of electrical power
• Dual
41 voltage systems produced by the alternator, between 1.5 and
12 V, 24 V. 2W of engine power consumed.
Power management system
a feature
supported on
certain vehicles
that actively
measures the
power utilization
and dynamically
adapts to the
power
resources
An intelligent power management system, however, may become more

financially attractive as electronic components continue to become
cheaper.
42
Charge balance calculation
used to ensure that the alternator cover all the demands
placed on it and still charge the battery.
1. Add the power used by all the continuous and
prolonged loads.
2. Total continuous and prolonged power (P1)=440 W.
3. Determine the intermittent power (factored by 0.1)
(P2)=170W
4. Total power (P1 + P2) = 610W
5. Total current 610/14 = 44A.
The rated output should be about 1.5 times the total

current demand (in this example 44 X 1.5 = 66 A).
Manufacturers produce machines) alternators) of

standard sizes, which in this ease would probably
mean an alternator rated at 70 A.
43
The final check is to ensure that the alternator
output at idle speed is large enough to supply
all continuous and prolonged loads (31.5 A)
and still charge the battery.
Again the factor of 1.5 can be applied to

continuous and prolonged loads(31.5 X 1.5) 47 A,
On normal systems this relates to an alternator

speed of about 2000 rev/min (or less). This can
be checked against the characteristic curve of
the alternator.
44
Alternator characteristics
Show the properties The rated output :about 1.5 times
of the alternator under the total current demand, 66A
different conditions
• Cut in speed.
• Idle speed range.
• Idle current output
range.
• Speed at which 2/3
of rated output is
reached.
• Current 2/3 of rated Idle current
output. output
• Rated output and
rated output speed.
• Maximum speed. Cut in speed
• Maximum output.
45
Efficiency of the alternator.
Efficiency = Power out/Power in
In this case, the efficiency at 8000 rev./min (rated output)

is:- (Power out = l4V x 68A = 952W)
952W/ 2200W =0.43 or about 43%
Efficiency at 2/3 maximum output

(Power out 14 V x 44 A =616 W)
616/1200W = 0.51 or about 51%
These figures help to illustrate

how much power is lost in the
generation process.
46 Automotive electrical and electronic systems,
charging system

2 - Charging System

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2 - Charging System

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Charging systems

The ‘current’ demands made by modern vehicles

The charging system must be able to meet these

The alternator generates AC but must produce DC

3 Automotive electrical and

180 + 260 + 170 =610W

Automotive electrical and

•In a practical alternator,

•Stator consists of three separate phases, each with a number of

Each end of the rotor will become a

The three-phase windings of the stator can be connected in two

A delta connection: type of parallel circuit.

where :V- output voltage; Vp- phase voltage;

An alternator when the engine is at idle, will have a

The negative cycles are

four-diode bridge rectifier

it will still require a small

They used to:-

•This can increase the

28 Automotive electrical and

29 Automotive electrical and

The whole switching

32 Automotive electrical and

The mechanical type

Zener diode can be

Zener diode can be

36 Automotive electrical and

Most systems in use at present tend to be alternator

A second sensing system (Sense the battery voltage)

40 Automotive electrical and

improving the output of

An intelligent power management system, however, may become more

The rated output should be about 1.5 times the total

Manufacturers produce machines) alternators) of

Again the factor of 1.5 can be applied to

On normal systems this relates to an alternator

In this case, the efficiency at 8000 rev./min (rated output)

Efficiency at 2/3 maximum output

These figures help to illustrate

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