8.

Charging Systems
Automotive – Ignition & Charging Systems

Charging Systems

Topics covered in this presentation:

 Charging System Components and Operation
 Alternator Construction and Operation

ClassAct SRS enabled.

8. Charging Systems
Automotive – Ignition & Charging Systems

The Function of the Charging System

Functions only when engine is running.

The charging system:

 Charges the battery. Generator

 Supplies power to all electrical systems.

Early vehicles used DC generators. Electricity Alternator

was generated by a rotor spinning within a
magnetic field (opposite of a DC motor).

Modern vehicles use alternators. Electricity is

generated in the stationary stator windings by a
spinning magnet (rotor with an energized field
winding and iron finger poles). Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 1
When does the charging system NOT function?

A) When the ignition is switched off

B) When the engine is running

C) When stationary at lights

D) When braking hard

8. Charging Systems
Automotive – Ignition & Charging Systems

Basic Charging System Components

Typical components are: Charge
warning
 The Alternator: Uses mechanical Battery lamp
power to produce electricity.

 Alternator Drive Belt: Drives

alternator from crankshaft.

 Charge Warning Lamp:

Displays charging system
information.

Drive belt
 The Battery: Supplies
voltage to alternator.
Alternator

Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Charging System Operation Alternator

pulley

Engine off, battery supplies

electricity to systems.

Current
Engine running, charging
flow
system supplies electricity Load
13 - 15 volts
to systems.

Battery
The alternator is driven
from the crankshaft pulley.
Alternator and
engine running
Its output voltage varies
between 13 and 15 volts.

This is sufficient to Crankshaft

charge the battery. pulley
Drive belt
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 2
What is the maximum output voltage of an alternator?

Enter your answer and press SEND.

8. Charging Systems
Automotive – Ignition & Charging Systems

The Alternator (External Side View)

Mounting
Typical alternator construction:
ear Regulator,
rectifier and
brush cover

Drive pulley
Output
terminal B+

Cooling fan Circulation

vents

Drive frame
cover End frame
cover Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 3
What makes the centre shaft of the alternator turn?

A) Electricity from the battery

B) Crankshaft movement drives the pulley belt

C) Air circulation through the vents

D) Electricity from the regulator, rectifier and brushes

8. Charging Systems
Automotive – Ignition & Charging Systems

The Alternator (External Rear View)

Typical rear terminals:
Connector containing:
IG terminal: Voltage
in from ignition switch
to power alternator
S terminal: Senses
charging voltage
L terminal: used by
regulator to ground
warning lamp

B+ terminal:
Alternator output
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

The Alternator (Internal View) Slip ring

end
Typical components are: Rectifier housing
assembly
 The rotor: Rotating
field winding.
Voltage Retainer
regulator nut
 The stator: Stationary
induction winding.
End Drive
 Rectifier assembly: cover pulley
Diode rectifier bridge.
Stator
 Voltage regulator: Rotor
Regulates output voltage.
Casing
 Cooling fans: Provide retainer
bolts
air circulation.
Cooling fans Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Alternator Components - The Rotor

Brushes Iron, claw-
Typical rotor components:
shaped, finger
pole pieces
 The field winding is
wound over an iron core.

 The finger poles surround

the field winding.

 The field winding

is attached to the
slip rings.

 The brushes
transfer voltage to
Main
the slip rings.
shaft
 The rotor assembly is supported Slip Field winding
at each end by bearings. rings Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 4
As the rotor turns it provides a supply of electricity from it's slip rings.
Is this true or false?

Answer True or False.

8. Charging Systems
Automotive – Ignition & Charging Systems

Rotor Magnetic Field

When voltage is applied to the field winding, a magnetic field is created.
It saturates the finger poles, creating north and south poles.
Voltage in Stator
windings
Curved flux
lines
North and
south poles

As the rotor turns, alternating north and south magnetic fields are created.
Magnetic field strength = current flow + closeness of finger poles. Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Alternator Components - The Stator

The stator has 3 sets of evenly spaced windings.

Stator
They are held within a frame
of soft iron laminations. 3 outputs

The windings are interlaced

to produce AC voltages that
are 120° apart.

Output voltage depends upon

rotor speed and its magnetic
field strength.

The windings connect to a Soft iron

Enamel copper lamination
diode rectifier bridge.
wire windings

Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 5
How many sets of windings are in the stator?

Enter your answer and press SEND.

8. Charging Systems
Automotive – Ignition & Charging Systems

Question 6
What is the angle between the different sets of stator windings?

Enter your answer and press SEND.

8. Charging Systems
Automotive – Ignition & Charging Systems

Single Phase Voltage Induction

Single winding (stator).
+
Magnet (rotor).
0
When magnet rotates, it induces
voltage in the winding. - Winding
Rotor
Maximum voltage = when winding Magnetic
is cut by maximum flux. field

Occurs when magnet is at 90°

to winding.

When magnetic field direction

changes, induced voltage polarity
is reversed.
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 7
When does the stator produce the maximum voltage?

A) When a magnet is at 180 degrees to a winding

B) When a magnet is at 90 degrees to a winding

C) When a magnet is at 120 degrees to a winding

D) When a magnet is at 45 degrees to a winding

8. Charging Systems
Automotive – Ignition & Charging Systems

Three Phase Voltage Induction

The stator has 3 windings, that
are 120° apart.
As the magnet rotates, it induces
voltages in all 3 windings.
The voltages produce a stable + 120°
3 phase output, ready for DC
conversion (rectification).
0 or Delta configurations.
The windings are connected in either0 Star 180 360

-
Star Delta

Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Rectification
Anode + - Cathode
Diodes allow current to flow
in only one direction.
+ Output
Diode
They conduct when a forward emf
voltage is applied to the anode. -
AC
voltage Battery
In this case, the positive
part of an AC voltage.
+ Output
emf
If 4 diodes are connected to D4 -
make a bridge, current can AC D1
flow during positive and voltage D2
Battery
negative parts of the AC D3
voltage, producing a totally
positive (DC) output.
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Alternator Components - The Rectifier Bridge

Stator terminals
Converts 3 phase AC
voltage into DC voltage. Positive
diodes

The bridge is constructed Negative

using 6 diodes. diodes

‘B’ terminal

3 are used on the positive side

of the bridge and 3 are used
on the negative side.

The diodes are mounted

on a heat sink.
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 8
What is a circuit that converts an alternating voltage to a direct
voltage called?

A) Regulator circuit

B) Negative diode circuit

C) Rectifier circuit

D) 3 phase circuit
8. Charging Systems
Automotive – Ignition & Charging Systems

Three Phase Rectification

Two diodes are connected
to each stator winding.

The rectification process

creates 3 positive voltages.

Rectifier
They are added output
together to
form a DC voltage that has
a small ripple.
Stator output Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Basic Three Phase Rectifier Operation

Rotor at winding 1,
induced voltage is applied
to battery +, via D1.
+
Return path from battery
- is via D5 and D6 to -
windings 2 and 3.

Rotor at winding 2,
induced voltage is applied
to battery +, via D3.

Return path from

battery - is via D4 and
D5 to windings 1 and 3. Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Rotor Field Excitation

The rotor requires voltage to produce a magnetic field.

Engine stopped, ignition

on, battery voltage is
applied to rotor, via
charge warning lamp.

Lamp is on and
current flows through
rotor winding.

Engine running,
alternator speed increases,
voltage output also increases.
Alternator voltage > battery voltage = lamp out, battery being
charged = alternator current flowing through rotor, via field diodes.
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Alternator Components - Voltage Regulator

Rotor field winding voltage must be
regulated to maintain alternator
output at specified voltage level.

The voltage regulator senses

alternator output and changes
field winding current.

Output voltage < specified, regulator

increases field winding current, output
voltage increases.

Output voltage > specified, regulator

decreases field winding current, output
voltage decreases.
Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 9
What controls the current in the rotor field coils to ensure the
output voltage is as specified?

A) Rectifier circuit

B) Regulator

C) Diodes

D) Current through the rotor

8. Charging Systems
Automotive – Ignition & Charging Systems

Typical Voltage Regulator Circuit

Regulation voltage is set by voltage drop across R1, ZD and T1.

Battery voltage < 14.2V, ZD does not conduct,

T1 off, T2 on, rotor current = max.
Alternator voltage >= 14.2V, ZD conducts, T1 on, T2 off, rotor current = 0.
Rapid switching of transistors provides a stable output voltage. Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Other Alternator Components

The carbon brushes supply voltage to
the rotor winding, via two slip rings.

The slip rings connect the rotating

field winding to the carbon brushes.

The drive pulley is fitted to the

end of the rotor shaft and driven
by a belt, from the crankshaft.

The cooling fans provide air to

cool alternator components.

Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Question 10
What material are the brushes made from?

A) Plastic

B) Copper

C) Brass

D) Carbon
8. Charging Systems
Automotive – Ignition & Charging Systems

Typical Alternator Circuit

Charge warning
A typical alternator circuit is shown below. lamp and
ignition switch
Rotor Rectifier
Regulating circuit

Starter
solenoid
Battery

Stator
Field diodes

The regulator senses alternator voltage at the starter solenoid. Next >
8. Charging Systems
Automotive – Ignition & Charging Systems

Summary
You should now be aware of:

 Charging System Components

and Operation

 Alternator Construction and Operation

End >