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Item 7 Automotive Technology: Principles, Diagnostics and Service by James Halderman Automotive Technology: Principles, Diagnostics and Service by James Halderman54.1 Explain why an alternator creates alternating current and changes it to direct current. Describe the construction of the alternator, including the drive pulleys. Describe the parts and operation of an alternator Discuss how an alternator works.
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54.5 List the factors that determine the output voltage and current of an alternator.diagnostics and system repair).
Terminology The Society of Automotive Engineers (SAE) term for a unit that produces electricity is a generator. In the profession, the term alternator is used more often. Principles: The amount of current produced can be increased by: Increasing the speed of the conductor through the magnetic field Increasing the number of conductors passing through the magnetic field Increasing the strength of the magnetic field
Housing The alternator is constructed using a two-piece die-cast aluminum housing The front bearing is pressed into the front housing, called the drive housing (DE) The rear housing, or slip ring housing (SRE), usually contains either a roller bearing or a
7 ANSWER 1: Increase the speed of the conductors, increase the number of conductors, increase the strength of the magnetic field.
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Purpose and Function The purpose of this pulley is to help eliminate noise and vibration in the auxiliary drive belt system. Can use an internal damper spring as well as a one-way clutch System Names Manufacturer Specific Isolating Isolation Pulley (IDP) Active Alternator Pulley (AAP) ) Alternator Isolation Pulley (ADP) Alternator Separation Pulley
9 Figure 54.1 Typical alternator on a Chevrolet V-8 engine driven by an auxiliary drive belt at the front of the engine
10 Figure 54.2 The end frame towards the drive belt is called the drive end housing and the back end is called the slip ring end housing
13 Figure 54.5 The alternator damper (OAD) is not a simple one-way clutch or solid pulley, but is designed to reduce noise and vibration in the front auxiliary drive belt system.
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Rotor Construction The rotor is made of many turns of copper wire coated with varnished insulation wound over an iron core. How Rotors Create Magnetic Fields The current through the slip rings causes the ‘fingers’ of the rotor to become alternating north and south magnetic poles.
Rotor current Maximum alternator rating in amperes depends on the number and diameter of the rotor windings Stator construction The stator consists of fixed coil windings inside the alternator Semiconductor diode that acts as a one-way electric non-return valve
18 Figure 54.6 Cross-section of an alternator, showing the rotor and cooling fan used to push air through the unit to remove the heat generated when it charges the battery and supplies electricity to the vehicle
Figure 54.7 Rotor assembly of a typical alternator. The current through the slip rings causes the rotor ‘fingers’ to become alternating north and south magnetic poles.
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20 Figure 54.8 Enlarged view of a typical alternator showing all its internal parts, including the stator windings
21 Figure 54.9 A rectifier usually comprises six diodes in an assembly and is used to rectify the alternating voltage from the stator winding into a direct current suitable for use in batteries and electrical appliances in the vehicle
A field current is created The magnetic field of the rotor creates a current in the stator windings by electromagnetic induction. Induced current in the stator The induced current in the stator windings is an alternating current due to the alternating magnetic field of the rotor.
Star-Connected Stators In a star-connected stator, the currents must combine because the two windings are always connected in series. Delta connected stators The current induced in each winding flows to the diodes in a parallel circuit.
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24 Figure Magnetic lines of force crossing the conductor induce voltage and current in the conductor
25 Figure The voltage curve of a sine wave (shaped like the letter S on the side) is created by a rotation of the winding while rotating in a magnetic field
26 Figure When there are three windings (A, B and C) in the stator, the resulting current output is represented by three sine waves. The voltages are 120 degrees out of phase. By connecting individual phases, a three-phase alternating voltage is created
28 Figure As the magnetic field created in the rotor cuts the stator windings, a current is induced. Current flow through the diodes converts the alternating voltage produced in the stator windings into a direct current voltage available at the output terminal of the alternator
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The output voltage and current of the alternator depends on the following factors. Rotation speed Number of conductors Magnetic field strength
Regulator Operation Field current control is achieved by opening and closing the ground side of the field circuit through the rotor in most alternators. The zener diode is the main electronic component that allows voltage regulation. Battery condition and charging voltage The alternator can supply the required current but may not reach the maximum charging voltage. Voltage regulators compensate for temperature.
Figure 37 Coolant exchanger showing the hose connections where the engine coolant flows through the rear frame of the exchanger
Computers can be connected to the charging system in three ways. The computer can activate the charging system by turning the field current on the rotor on and off. The computer can monitor the operation of the alternator and increase the engine speed. The computer can control the alternator by controlling the output of the alternator according to the needs of the electrical system.
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41 Figure A Hall current sensor connected to the positive battery cable is used as part of the EPM system
43 Diagram 54-1 The output voltage is controlled by changing the duty cycle controlled by the PCM.
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