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CHAPTER
Charging Systems/ 7
Charging System Testing and Service
Upon completion and review of this chapter, you should be able to understand and describe:
Reading Assignments
Classroom Manual, pages 170-208
Shop Manual, pages 283-316
Terms to Know
Current output test Full-wave rectification Sensing voltage
Delta connection Half-wave rectification Slip rings
Diode rectifier bridge Heat sink Stator
Diode trio Inductive reactance Voltage drop test
Electronic regulator EVR Multiplying coil Voltage output test
Field current draw test Pulse width modulation Wye wound connection
Full fielding Rectification
Full field test Rotor
I. Objectives
Review the chapter's objectives.
II. Introduction
Explain the complete charging circuit and why it is needed.
IV. AC Generators
Describe the basic components that make up an AC generator.
A. Rotors: Describe the construction and operation of rotors, including the fact that
the rotor develops a magnetic field when it is energized.
B. Brushes: Explain that one brush supplies power to the rotor and the other supplies
ground.
C. Stators: Describe the operation of a stator and explain the two ways in which the windings may
be wound (wye and delta).
D. Diode Rectifier Bridge: Explain how diode rectifier bridges work; talk about positive and negative
diodes. Mention that older AC generators used diodes that could be replaced individually. This
design has been largely superseded by rectifier bridge designs. Discuss half-wave and full-wave
rectification.
E. AC Generator Housing and Cooling Fan: Explain how the cooling fan draws air through the AC
generator.
F. Liquid-cooled generators: Explain the need for liquid-cooled generators in high-output systems.
V. AC Generator Circuits
Describe the three AC generator circuits - the pre-excitation circuit, which provides the initial rotor
field current; the excitation circuit, which consists of the rotor field coil and the electrical connections
that provide it with power and ground; and the charging circuit, which consists of the stator windings
and rectifier circuits and is the place where the voltage is actually induced in the generator.
VII. Regulation
Explain the need for a voltage regulator in a charging system.
A. Field Circuits
Explain how the regulator controls the field circuit; talk about A and B type designs.
B. Electronic Regulators
Describe the operation of electronic voltage regulators (including how they sense system
voltage) and explain why they are superior to electro-mechanical voltage regulators.
C. Computer-Controlled Regulation
Describe the operation of computer-controlled field circuits, where voltage regulation is
controlled by the vehicle's on-board computer. Discuss the concept and advantages of pulse
width modulation.
XXIX. Summary
Review the material covered, emphasizing the main points and key words.
Chapter 7 Answers to Review Questions
1. The charging system consists of the battery, AC generator or DC generator, drive belt, voltage
regulator, charge indicator (lamp or gauge), ignition switch, cables and wiring harness, starter relay
(some systems), and fusible links (some systems).
2.
1) Rotor—Creates the rotating magnetic field of the AC generator. It is the portion of the AC
generator that is rotated by the drive belt.
2) Brushes—The insulated stationary carbon brush passes field current into a slip ring, then
through the field coil, and back to the other slip ring. Current then passes out of the grounded
stationary brush.
3) Stator—The stationary coil that current is produced in. It contains three main sets of windings
wrapped in slots around a laminated, circular iron frame.
4) Diode rectifier bridge—Provides reasonably constant DC voltage to the vehicle's electrical
system and battery. The diode rectifier bridge is used to change the current in an AC generator.
5) Housing—Most AC generator housings are two-piece construction, made from cast aluminum.
The two end frames provide support of the rotor and the stator. In addition, the end frames
contain the diodes, regulator, heat sinks, terminals, and other components of the AC generator.
6) Cooling fan—Draws air into the AC generator through the openings at the rear of the AC
generator housing. The air leaves through openings behind the cooling fan.
3. Field current is what determines how much output is produced by the generator. The greater the
field current, the greater the magnetic field strength that is produced by the rotor, which then
produces more current in the stator windings.
4.
1) A circuit—The regulator is on the ground side of the field coil. The B+ for the field coil is picked
up from inside the AC generator. By placing the regulator on the ground side of the field coil, the
variable resistance will allow the control of field current by varying the current flow to ground.
2) B circuit—The voltage regulator controls the power side of the field circuit. Also, the field coil is
grounded from inside the AC generator. Usually the B circuit regulator is mounted externally of
the AC generator. The B circuit is an internally grounded circuit.
3) Isolated circuit—The AC generator has two field wires attached to the outside of the case. The
voltage regulator can be located on either the ground (A circuit) or on the B+ (B circuit) side. AC
generators pick up B+ and ground externally.
5. Most indicator lamps operate on the basis of voltage drop. If the AC generator output is less than
battery voltage, there is an electrical potential difference in the lamp circuit and the lamp will light.
6.
1) Wye connection—In the wye connection, one lead from each winding is connected to one
common junction. From this junction, the other leads branch out in a Y pattern.
2) Delta connection—The delta connection connects the lead of one end of the winding to the lead
at the other end of the next winding.
7. Half-wave rectification uses a single diode for each stator winding to allow current to flow in one
direction.
Therefore, as AC current passes through a positively biased diode, the negative portion of the cycle
is blocked.
Full-wave rectification uses at least two diodes for each stator winding to rectify both sides of the
AC sine wave. This process inverts the negative cycle and makes it into a positive current.
8. Note: Student's answer should have the context of each element.
An AC generator usually uses a pair of diodes for each stator winding. Three of the diodes are
positive biased and are mounted in a heat sink. The three remaining diodes are negative biased
and are attached directly to the frame of the AC generator. By using a pair of diodes that are
reversed biased to each other, rectifying of both sides of the AC sine wave is achieved. The
negative biased diodes allow for conducting current from the negative side of the AC sine wave and
putting this current into the circuit. Diode rectification changes the negative current into positive
output. With each stator winding connected to a pair of diodes, the resultant wave form of the
rectified voltage would have six peaks per revolution and the voltage will vary by only a couple of
volts during each cycle. Each pair of poles produces one complete sine wave in each winding per
revolution. The rotor generates three overlapping sine wave voltage cycles in the stator.
9. The purpose of the charging system is to convert the mechanical energy of the engine into electrical
energy to recharge the battery and run the electrical accessories.
10. Regenerative braking means that the electric motor becomes a generator, acting as an electric
brake to slow the vehicle.
Fill-In-The-Blanks
1. Mechanical, electrical (in order)
2. Electromagnetic induction
3. Rotor
4. Brushes
5. Wye
6. Voltage regulator, field (in order)
7. Pulse-width modulation
8. three
9. stator
10. regenerative braking, electrical (in order)
Multiple Choice
1. A
2. C
3. D
4. C
5. A
6. D
7. C
8. A
9. C
10. C
§ 5. Chaldæan Sculpture.