AFM - L2 - S1 New-2

19AUOC1001
Automotive Fundamentals and

Manufacturing
Online Lecture-23
BHARATHIRAJA R
ASSISTANT PROFESSOR [MECH]
Dr.Mahalingam College of Engineering &
Technology - Pollachi
Dept of Mech 19AUOC1001-AFM

Course Type : Open Elective Course Categories : Mastery Courses
Total Hours-45 IIIrd Year

[2019-2023 Batch]

Course Outcome
Explain the functions and quality parameters of given
sub-systems in Electrical and Electronic System of
automotive products.
Learning Outcome 2
Explain the charging system of the automotive vehicle.
•Different types of charging system used in the automotive

vehicle

UNIT IV
ELECTRICAL AND
ELECTRONIC SYSTEMS

Charging System
Dept of Mech LO 4.2 19AUOC1001-AFM

Introduction
Charging system maintains the charge in the

vehicle's battery, and also provides electrical energy
to electrical loads while the engine is running.
Charging system in two-wheelers consist of the

magneto, regulator, battery and the interconnecting
wiring.

Why Charging System?
It is to provide necessary electrical power to the
electrical parts which are used for :
Homologation Requirements
•Horn
•Headlamp, Indicators, Brake lamp, etc.
•Speedometer indications
Night Driving Conditions
•Position lamps
Engine electric start
•Convenient starting
DC Ignition
•Enhanced start-ability and spark

Functions of Charging System
The charging system has a primary function of

maintaining the battery in an optimum charged
condition.
Secondary functions are

•Enable functioning of electrical loads without battery
also.
•Provide the required output with minimum ripple and
voltage spikes.

Functional Block Diagram

Power Generation
 In motor vehicles the mechanical power generated by
engine via manual kicking or Auxiliary electrical storage
such as Battery can be utilized to generate power.
 This is done by means of a Magneto, which is a single

phase AC generator with permanent magnets.
 In this case, permanent magnets act as rotor and

winding across limbs as stator through which electrical
output is taken.
 Electrical power generated depends on engine speed.

Power Conditioning
 The two important functions of this stage are:

1.Regulation
2.Rectification
 Regulation – To control the power supplied to the

electrical loads.
-Linear or switching regulators.
 Rectification – AC to DC conversion.
(with power semiconductor devices)

Auxiliary Storage
 Auxiliary storage is necessary to store energy for using

electrical loads in the engine OFF condition.
• A battery can be used as an auxiliary energy storage

device.
• The capacity required depends on the DC loads in

each vehicle.

Subsystem Parts
 Magneto Assembly
 Regulator cum Rectifier Unit
 Battery
 External capacitor (in RTR-FI)

Magneto
The Magneto is used for
•Generating and providing power for the lamps, horn,

battery, etc on the vehicle in running condition.
•Generating and providing power for creating spark in the

spark plug for vehicles with AC ignition system.
•Acting as a flywheel, thereby providing inertia and also

minimizing torque transients in the engine.
•Providing ignition timing signal through the pulser coil

and rotor pip.

How a Magneto Works?
•The Magneto works on the principle of
a single phase AC Generator.
•The basic law that governs the AC

generator principle is the Faraday’s Law
Hence whenever there is a relative motion between the conductor and

the magnetic field, electricity can be produced.
In a magneto, permanent magnets are fitted on the rotating part

(rotor) which creates a varying magnetic field.
The conductors (copper windings) are wound on the stationary part.

Whenever the windings experience a change in the magnetic field, a
voltage is developed. The rate of change (acceleration and speed) of
the engine are vital factors that affect the output of magneto.

Magneto Assembly
•Rotating part of magneto assy.

Holds magnets
•Provides inertia
•Contains the pip for ignition timing
Stationary part of magneto assy

has windings to cut the magnetic field
Contains :
•Charging coil
•Lighting coil
•Source coil (only for AC ignition systems)
•Pulser coil
Video

RR Unit
The Regulator cum Rectifier unit is used for
Giving a Controlled AC voltage output - For loads which operate

only when engine is running.
Converting AC to controlled DC output – For loads which can

operate when engine is OFF.

R.R. Unit - Regulation
• Regulation means controlling the output voltage within a
specified limit (ie.,14 ± 0.5 V).
• The two configurations that can be used for regulation
are:
Shunt
 Preferred for generators that do not produce excess
current when shunted.
 More heat is produced at low loads
Series
 Only the necessary load current runs at any time.
 The result is less heating when operated low electrical
load.

R.R. Unit - Rectification
Rectification means conversion of AC to DC power. The two
configurations that can be used for rectification are:
Full Wave: Half Wave:

•Both the halves of the sine •Only the positive half of the sine
wave are utilized. wave is utilized.
•Better efficiency as the power •Half the efficiency of the full wave
utilization is more. configuration.
•Used in Apache RTR-FI, Flame •Used in Star, Scooty, Apache RTR

R.R. Unit – Connection Diagram

Battery
The battery supplies electricity when the:
ENGINE IS OFF:
Electricity from the battery is used to operate lighting, accessories, or
other electrical systems when the engine is not running.
ENGINE IS STARTING:
Electricity from the battery is used to operate the starter motor and to
provide current for the ignition system during engine cranking.
ENGINE IS RUNNING:
Electricity from the battery is needed to supplement the charging
system when the vehicle's electrical load requirements exceed the
charging system's ability to produce electricity. Both the battery and
the magneto supply electricity when demand is high.
Typical automotive batteries have a nominal voltage of 12V.

Battery - Types
PRIMARY CELL:
Because the chemical reaction totally destroys
one of the metals after a period of time, primary
cells cannot be recharged. Small batteries such
as flashlight and radio batteries are primary
cells. Under this there are types like Zinc
Chloride, Mercury, alkaline, etc.
SECONDARY CELL:
By applying current to the battery in the reverse
direction, the battery materials can be restored,
thus recharging the battery. This process is called
charging. Automotive lead-acid batteries are
secondary cells and can be recharged. Under this
there are types like NiMH, Pb acid, Li Ion, etc

Lead Acid Battery - Construction
Lead acid battery is widely used in automobiles.
Lead acid battery is the popular choice in automotive Contains
a diluted sulfuric acid electrolyte and positive and negative
electrodes, in the form of several plates.
A battery is separated into several cells (usually six in the case
of automobile batteries), and in each cell there are several
battery elements, all bathed in the electrolyte solution.

Lead Acid Battery - Construction
Principle
•Changes Chemical Energy to Electrical Energy (Chemical Compound
Alkali, salt or acid solution is capable of Conducting Electricity)
• Two dissimilar Plates(Eg. Lead & Lead Peroxide) immersed in the
Electrolyte solution causes Electricity

Battery - Types
Batteries can be produced as Wet-Charged, such as current
automotive batteries are today, or they can be Dry-Charged,
where an electrolyte solution is added when put into service.
WET-CHARGED: The lead-acid battery is filled with electrolyte

and charged when it is built. During storage, a slow chemical
reaction will cause self-discharge. Periodic charging is required.
Most batteries sold today are wet charged.
DRY-CHARGED: The battery is built, charged, washed and dried,
sealed, and shipped without electrolyte. It can be stored for up to
18 months. When put into use, electrolyte and charging are
required. Batteries of this type have a long shelf life. Some
motorcycle batteries are typically dry charged batteries (eg.
Export).

Battery Terminologies
1.Ampere-Hour Rating
5Ahr ----------- 5 Amps * 1 hr
0.5Amps * 10hrs
2.High Rate Discharge Rating

•Discharge current is 40 A. for 5Ah Battery,
•Voltage After 5 Sec. Is 9.8V
•Discharge final Voltage is 6V after at least 78 Sec.

Types of Charging
A wide variety of schemes exist for charging lead-acid
batteries. The common methods are :
1.Constant Voltage : In this method, a constant voltage
input is maintained throughout the charging process. This
enables high initial current to the battery as the potential
difference is high in the initial stage.
2.Constant Current : In this method, a uniform current is
supplied throughout the charging process. This eliminates
imbalances of the cells.
In two wheelers, charging is predominantly constant

voltage mode at the suitable engine rpm.

Quality Characteristics
Magneto
1.Output voltage
2.Rated rpm
3.Power output
4.Taper Matching
5.Stator Mounting
6.Amount of Unbalance
If the unbalance is high, the rotor will wobble which leads to

•Less power from magneto and hence improper ignition leading to loss
of power and mileage and more emission.
•Leads to engine vibration because of torque variation
If taper matching is less
•There will not be proper locking of rotor with crankshaft and hence
damage to both crankshaft and rotor.

RR Unit
1.Output voltage (with & without Battery)
2.Rated rpm
3.Battery charging current
4.Spike level
5.Load Regulation
6.Mounting on chassis

Battery
1.Open circuit Voltage
2.Specific gravity
3.Battery Life
4.Electrolyte level
5.Discharge capacity
Achieving Quality characteristics @ design stage
1.Design Specifications
2.Charge balance test

Design Specifications
Major quality characteristics are the output voltage and current in the
charging system

Design Specifications

Charge Balance test
 A method to capture the parameters of charging system such as
Voltage, Current and Temperature of the battery.
 The measuring system captures the Real-time Capacity (Ampere-
hour) of the battery.
 System captures the data at minimum intervals ( more than 30
samples / minute).

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19AUOC1001

Automotive Fundamentals and

Dept of Mech 19AUOC1001-AFM

Total Hours-45 IIIrd Year

Dept of Mech 19AUOC1001-AFM

•Different types of charging system used in the automotive

Dept of Mech 19AUOC1001-AFM

Dept of Mech 19AUOC1001-AFM

Dept of Mech LO 4.2 19AUOC1001-AFM

Charging system maintains the charge in the

Charging system in two-wheelers consist of the

Dept of Mech LO 4.2 19AUOC1001-AFM

Dept of Mech LO 4.2 19AUOC1001-AFM

The charging system has a primary function of

Secondary functions are

Dept of Mech LO 4.2 19AUOC1001-AFM

Dept of Mech LO 4.2 19AUOC1001-AFM

 This is done by means of a Magneto, which is a single

 In this case, permanent magnets act as rotor and

 Electrical power generated depends on engine speed.

Dept of Mech LO 4.2 19AUOC1001-AFM

 The two important functions of this stage are:

 Regulation – To control the power supplied to the

Dept of Mech LO 4.2 19AUOC1001-AFM

 Auxiliary storage is necessary to store energy for using

• A battery can be used as an auxiliary energy storage

• The capacity required depends on the DC loads in

Dept of Mech LO 4.2 19AUOC1001-AFM

 Regulator cum Rectifier Unit

 External capacitor (in RTR-FI)

Dept of Mech LO 4.2 19AUOC1001-AFM

The Magneto is used for

•Generating and providing power for the lamps, horn,

•Generating and providing power for creating spark in the

•Acting as a flywheel, thereby providing inertia and also

•Providing ignition timing signal through the pulser coil

Dept of Mech LO 4.2 19AUOC1001-AFM

•The basic law that governs the AC

Hence whenever there is a relative motion between the conductor and

In a magneto, permanent magnets are fitted on the rotating part

The conductors (copper windings) are wound on the stationary part.

Dept of Mech LO 4.2 19AUOC1001-AFM

•Rotating part of magneto assy.

Stationary part of magneto assy

Dept of Mech LO 4.2 19AUOC1001-AFM

Giving a Controlled AC voltage output - For loads which operate

Converting AC to controlled DC output – For loads which can

Dept of Mech LO 4.2 19AUOC1001-AFM

Dept of Mech LO 4.2 19AUOC1001-AFM

Full Wave: Half Wave:

Dept of Mech LO 4.2 19AUOC1001-AFM

Dept of Mech LO 4.2 19AUOC1001-AFM

Dept of Mech 19AUOC1001-AFM

Dept of Mech 19AUOC1001-AFM

Dept of Mech 19AUOC1001-AFM

Dept of Mech 19AUOC1001-AFM

WET-CHARGED: The lead-acid battery is filled with electrolyte

Dept of Mech 19AUOC1001-AFM

2.High Rate Discharge Rating

Dept of Mech 19AUOC1001-AFM

In two wheelers, charging is predominantly constant

Dept of Mech 19AUOC1001-AFM

If the unbalance is high, the rotor will wobble which leads to