Chapter 21 LectureNotes

CHAPTER 21
Charging System
Automotive Electricity and Electronics, 3/e
By James D. Halderman
Copyright 2011, 2009, 2005 Pearson Education, Inc.,
Upper Saddle River, NJ 07458 All rights reserved.
2
OBJECTIVES
After studying Chapter 21, the reader will be able to:
1. Prepare for ASE Electrical/Electronic Systems
(A6) certification test content area D (Charging
System Diagnosis and Repair).
2. List the parts of a typical alternator.
3. Describe how an alternator works.
4. Explain how the powertrain control module
(PCM) controls the charging circuit.
3
KEY TERMS
Alternator
Claw poles
Delta winding
Diodes
Drive-end (DE) housing
Duty cycle
EPM
IDP
OAD
OAP
Rectifier
Rotor
Slip-ring-end (SRE)
housing
Stator
Thermistor
4
PRINCIPLES OF ALTERNATOR
OPERATION
TERMINOLOGY
It is the purpose and function of the charging
system to keep the battery fully charged.
PRINCIPLES
All electrical alternators use the principle of
electromagnetic induction to generate electrical
power from mechanical power.
Electromagnetic induction involves the generation of
an electrical current in a conductor when the
conductor is moved through a magnetic field.
CHANGING AC TO DC
5
ALTERNATOR CONSTRUCTION
HOUSING
An alternator is constructed using a two-piece cast
aluminum housing.
A front ball bearing is pressed into the front housing,
called the drive-end (DE) housing , to provide the
support and friction reduction necessary for the belt-
driven rotor assembly.
The rear housing, or the slip-ring-end (SRE)
housing , usually contains either a roller bearing or
ball bearing support for the rotor and mounting for
the brushes, diodes, and internal voltage regulator
(if so equipped).
6
HOUSING
FIGURE 211 A typical alternator on a
Chevrolet V-8 engine.
7
HOUSING
FIGURE 212 The end frame toward
the drive belt is called the drive-end
housing and the rear section is called
the slip-ring-end housing.
8
ALTERNATOR OVERRUNNING PULLEYS
PURPOSE AND FUNCTION
Many alternators are equipped with an
overrunning alternator pulley (OAP) , also called
an overrunning clutch pulley or an alternator clutch
pulley .
The purpose of this pulley is to help eliminate
noise and vibration in the accessory drive belt
system, especially when the engine is at idle
speed.
9
FIGURE 213 An OAP on a Chevrolet Corvette alternator.
10
FIGURE 214 An exploded view of an
overrunning alternator dampener showing
all of the internal parts.
11
Alternator Horsepower and Engine
Operation
Many technicians are asked how much power
certain accessories require. A 100 ampere
alternator requires about 2 horsepower from
the engine. One horsepower is equal to 746
watts. Watts are calculated by multiplying
amperes times volts.
Power in watts = 100 A x 14.5 V = 1,450 W
1 hp = 746 W
Therefore, 1,450 watts is about 2 horsepower.
12
Can I Install an OAP or an OAD to My
Alternator?
Usually, no. An alternator needs to be
equipped with the proper shaft to allow the
installation of an OAP or OAD. This also
means that a conventional pulley often cannot
be used to replace a defective overrunning
alternator pulley or dampener with a
conventional pulley. Check service information
for the exact procedure to follow.
13
Always Check the OAP or OAD First
Overrunning alternator pulleys and overrunning
alternator dampeners can fail. The most common
factor is the one-way clutch. If it fails, it can freewheel
and not power the alternator or it can lock up and not
provide the dampening as designed. If the charging
system is not working, the OAP or OAD could be the
cause, rather than a fault in the alternator itself.
In most cases, the entire alternator assembly will be
replaced because each OAP or OAD is unique for
each application and both require special tools to
remove and replace.
14
Always Check the OAP or OAD First
FIGURE 215 A special tool is needed to remove and install
overrunning alternator pulleys or dampeners.
15
ALTERNATOR COMPONENTS AND
OPERATION
ROTOR CONSTRUCTION
HOW ROTORS CREATE MAGNETIC FIELDS
ROTOR CURRENT
STATOR CONSTRUCTION
DIODES
DIODE TRIO
16
OPERATION
FIGURE 216 A cutaway of an alternator, showing the
rotor and cooling fan that is used to force air through
the unit to remove the heat created when it is charging
the battery and supplying electrical power for the
vehicle.
17
OPERATION
FIGURE 217 Rotor assembly of a typical
alternator. Current through the slip rings
causes the fingers of the rotor to
become alternating north and south
magnetic poles. As the rotor revolves,
these magnetic lines of force induce a
current in the stator windings.
18
OPERATION
FIGURE 218 An exploded view of a typical alternator showing all of its
internal parts including the stator windings.
19
OPERATION
FIGURE 219 A rectifier usually includes six diodes in
one assembly and is used to rectify AC voltage from the
stator windings into DC voltage suitable for use by the
battery and electrical devices in the vehicle.
20
HOW AN ALTERNATOR WORKS
HOW AN ALTERNATOR
WORKS
CURRENT IS INDUCED IN
THE STATOR
WYE-CONNECTED
STATORS
DELTA-CONNECTED
STATORS
FIGURE 2110 Magnetic lines of force cutting
across a conductor induce a voltage and
current in the conductor.
21
FIGURE 2111 A sine wave (shaped like the letter S on its side) voltage curve is created by one
revolution of a winding as it rotates in a magnetic field.
22
FIGURE 2112 When three windings (A, B, and C) are present in a stator, the resulting
current generation is represented by the three sine waves. The voltages are 120 degrees
out of phase. The connection of the individual phases produces a three-phase alternating
voltage.
23
FIGURE 2113 Wye-connected stator winding.
24
FIGURE 2114 As the magnetic field, created in the rotor, cuts
across the windings of the stator, a current is induced. Notice that
the current path includes passing through one positive (+) diode on
the way to the battery and one negative (-) diode as a complete
circuit is completed through the rectifier and stator.
25
FIGURE 2115 Delta-connected stator winding.
26
ALTERNATOR OUTPUT FACTORS
The output voltage and
current of an alternator
depend on the following
factors.
Speed of rotation
Number of conductors
Strength of the magnetic
field
FIGURE 2116 A stator assembly with six, rather
than the normal three, windings.
27
ALTERNATOR VOLTAGE REGULATION
PRINCIPLES
REGULATOR OPERATION
BATTERY CONDITION AND CHARGING
VOLTAGE
TEMPERATURE COMPENSATION
28
FIGURE 2117 Typical voltage regulator range.
29
FIGURE 2118 A typical electronic voltage regulator with the cover removed
showing the circuits inside.
30
FIGURE 2119 Typical General Motors
SI-style alternator with an integral
voltage regulator. Voltage present at
terminal 2 is used to reverse bias the
zener diode (D2) that controls TR2. The
positive brush is fed by the ignition
current (terminal I) plus current from the
diode trio.
31
ALTERNATOR COOLING
Alternators create heat during normal operation
and this heat must be removed to protect the
component inside, especially the diodes and
voltage regulator.
The types of cooling include:
External fan
Internal fan(s)
Both an external fan and an internal fan
Coolant cooled
32
ALTERNATOR COOLING
FIGURE 2120 A coolant-cooled alternator
showing the hose connections where coolant
from the engine flows through the rear frame of
the alternator.
33
COMPUTER-CONTROLLED
ALTERNATORS
TYPES OF SYSTEMS
GM ELECTRICAL POWER MANAGEMENT
SYSTEM
COMPUTER-CONTROLLED CHARGING
SYSTEMS
34
COMPUTER-CONTROLLED
ALTERNATORS
FIGURE 2121 A Hall-effect current sensor attached to the
positive battery cable is used as part of the EPM system.
35
COMPUTER-CONTROLLED
ALTERNATORS
FIGURE 2122 The amount of time current is flowing through the field
(rotor) determines the alternator output.
36
COMPUTER-CONTROLLED
ALTERNATORS
37
The Voltage Display Can Be a Customer
Concern
A customer may complain that the voltmeter
reading on the dash fluctuates up and down.
This may be normal as the computer-
controlled charging system commands various
modes of operation based on the operating
conditions. Follow the vehicle manufacturers
recommended procedures to verify proper
operation.
38
SUMMARY
1. Alternator output is increased if the speed of the
alternator is increased.
2. The parts of a typical alternator include the drive-
end (DE) housing, slip-ring-end (SRE) housing,
rotor assembly, stator, rectifier bridge, brushes,
and voltage regulator.
3. The magnetic field is created in the rotor.
4. The alternator output current is created in the
stator windings.
5. The voltage regulator controls the current flow
through the rotor winding.
39
REVIEW QUESTIONS
1. How can a small electronic voltage regulator
control the output of a typical 100 ampere
alternator?
2. What are the component parts of a typical
alternator?
3. How is the computer used to control an
alternator?
4. Why do voltage regulators include temperature
compensation?
5. How is AC voltage inside the alternator changed
to DC voltage at the output terminal?
6. What is the purpose of an OAP or OAD?
40
CHAPTER QUIZ
1. Technician A says that the diodes regulate the
alternator output voltage. Technician B says that
the field current can be computer controlled.
Which technician is correct?
a. Technician A only
b. Technician B only
c. Both Technicians A and B
d. Neither Technician A nor B
41
CHAPTER QUIZ
2. A magnetic field is created in the ________ in an
alternator (AC alternator).
a. Stator
b. Diodes
c. Rotor
d. Drive-end frame
42
CHAPTER QUIZ
3. The voltage regulator controls current through
the ________ .
a. Alternator brushes
b. Rotor
c. Alternator field
d. All of the above
43
CHAPTER QUIZ
4. Technician A says that two diodes are required
for each stator winding lead. Technician B says
that diodes change alternating current into direct
current. Which technician is correct?
44
CHAPTER QUIZ
5. The alternator output current is produced in the
________ .
a. Stator
b. Rotor
c. Brushes
d. Diodes (rectifier bridge)
45
CHAPTER QUIZ
6. Alternator brushes are constructed from
________.
a. Copper
b. Aluminum
c. Carbon
d. Silver-copper alloy
46
CHAPTER QUIZ
7. How much current flows through the alternator
brushes?
a. All of the alternator output flows through the
brushes
b. 25 to 35 A, depending on the vehicle
c. 10 to 15 A
d. 2 to 5 A
47
CHAPTER QUIZ
8. Technician A says that an alternator overrunning
pulley is used to reduce vibration and noise.
Technician B says that an overrunning alternator
pulley or dampener uses a one-way clutch.
48
CHAPTER QUIZ
9. Operating an alternator in a vehicle with a
defective battery can harm the ________.
a. Diodes (rectifier bridge)
b. Stator
c. Voltage regulator
d. Brushes
49
CHAPTER QUIZ
10. Technician A says that a wye-wound stator
produces more maximum output than the same
alternator equipped with a delta-wound stator.
Technician B says that an alternator equipped
with a delta-wound stator produces more
maximum output than a wye-wound stator.

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