Vehicle Charging System

International Islamic University Malaysia
Charging System
Dr. Md. Ataur Rahman
Department of Mechanical Engineering, Kulliyyah

of Engineering, IIUM
Automotive Charging System

The charging system converts mechanical energy into
electrical energy
IC engine powered car battery charges when engine runs.
Electrical car battery charges when the charger plug-in with 220
volt ac power.
The main function of automobile charging system is to

control and regulate the charge in the battery of a vehicle.
When the charging system voltage is more than the vehicle
electrical load needed, it sends to the battery for charging.
Automobile charging system generally generates a voltage

between 13.5 and 14.4 volts when the engine is working.
It produces electrical current for operating automobile
lights, music systems, heater, engine electrical system and
other electrical components.
Charging Voltage
The main consideration for the charging voltage
is the battery terminal voltage when fully
charged.
If the charging voltage is set to this fully charged
value then there is no risk of overcharging the
battery.
This is known as constant voltage charging technique
The 14.18 to 14.22 is the accepted charging voltage for a
12V battery
The charging system objective to meet the following criteria (when the
engine is running:
Supply the current demands made by all loads
Supply whatever charge current the battery demands
Operate at idle speed
Supply constant voltage under all conditions
Have an efficient power-to-weight ratio
Provide an indication of correct operation.
The main components of the charging system is the

alternator-with the exception of its associated wiring.
Rotor assembly of a typical alternator (AC generator).
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.
Alternator produces AC voltage which needs to convert to DC
voltage to charge the battery.
The output of the alternator must be a constant voltage regardsless
of the engine speed and current load.
The alternator generates AC but must

produce DC at its output terminal.
DC can be used to charge the
battery and run electronic circuits.
The output of the alternator must be
a constant voltage regardless of
engine speed and current load.
Magnetic lines of force cutting
across a conductor induce a
voltage and current in the
conductor.
Rectification of AC to DC
A vehicle electrical circuits and battery operate with direct current
(DC). The AC current produced by the alternator needs to be
converted to a DC voltage. This process is called rectification.
Rectification process is made with the sets of diodes
The simplest kind of semiconductor is called diode.
It is made of one layer of P-type material and one of N type material.
The point where two types materials joint is called junction.
The word of diode means having two electrodes
The (+ive) is anode and (- ive) is cathode.

It can function as a switch.
It is used in electronic circuit as a sort of one-way check valve that will conduct
electricity in one direction (forward) and block it in other direction (reverse).
In a DC generator, the split ring commutator is used to rectify AC voltage to DC voltage
In an AC generator, the AC voltage is rectified by diodes that act as an one-way check
valves, allowing current to flow in one direction only.
In a simple circuit, if AC voltage passes through a positively biased diode, the diode
will block the negative portion of sine wave.
To charge the battery and run vehicle components
It must be converted from alternating current (AC) to direct current (DC).
The common most suitable for this task is the silicon diode.
Rectifier circuit
If single phase AC are passed of an alternator to DC output
Single diode rectifier circuit
Its output will be half-wave rectification
The diode will allow the positive half cycle to be conducted towards
the positive of the battery
While, the negative cycle are blocked.
A four-diode bridge RC
Its output will be full-wave rectification.
The process of converting a complete waveform to a positive DC
waveform is called full-wave rectification.
Three phase AC are passed of an alternator to a DC

output
Series of six diodes rectifier circuit
One pair for each stator windings
Three of the diodes are positive biased and mounted in a heat sink
Three remaining diodes are negative biased and attached directly
to the alternator rear housing which also act like a heat sink
Alternator and Charging Circuits

Three phase alternator
Electromagnetic induction is caused by a rotating magnet inside a stationary loop
or loops of wire.
The stationary loop of wire are known as the stator and consist of three separate
phases, each with a number of windings.
The windings are mechanically spaced on a laminated core (to reduce eddy
currents).
Must be matched number of poles on the rotor
The three-phase windings of the stator can be connected in two ways:
Star
Delta
Star connection can be though of as a type of series connection of the phases
The output voltage across any two phases will be the vector sum of the
phase voltages
Current output will be the same as the phase current
Star-wound stators therefore, produce a higher voltage, whereas delta-wound
stators produce a higher current
Full-wave rectification in a delta wound is accomplished with the same

diode rectification of wye (star) wound stator.
Difference current flows from each winding all the time and this
increase the alternator output current compared to the wye wound
alternator.
While a good quality diode will block reverse flow up to a pressure of about
400V
It will require only a small voltage pressure of about 0.6V to conduct in the forward direction.
- 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.
Delta-connected
stator winding.
A star connection can be thought of as a type of series connection of the phases

If any of the phases is absent
The output voltage across any two phases will be the vector sum of the phases
voltage.
Current output will be same as the phase current.
A star-wound alternator produces a higher voltage than a delta-wound stator.
But, a delta-wound alternator produces a higher current than a star-wound
stator.
For a star-wound stator,
V = Vp 3
I = Ip
A delta connection can be thought of as a type of parallel circuit.

The output voltage will be the same of the phase voltage, but the
output current is the vector sum of the phase current.
For a delta-wound stator,
V =V p
I = Ip 3
where, V =output voltage, Vp=phase voltage, I=output current, Ip=phase

current
Heavy vehicle are used the delta connected/winding alternator

for the advantages of higher current output
But, most vehicle uses star winding alternator.
The frequency of an alternator output can be calculated as;
pn
60
where, f = Frequency in Hz, p = no. of pole pair (12 claw rotor has 6 pole pairs ),
f =
n = alternator speed in rpm
Charging System-Inducing EMF (Voltage)

Improving the Voltage Induction:
A magnetic field and a conductor or conductors are required.
Conductor must be movable (rotation-able)
Lines of force must be cut parallel movement has no effect.
Increasing the speed of cutting increases the induce of EMF or voltage
Increasing the strength increases the induced EMF
Increasing the number of conductors increases the induced EMF.
Charging System Field Diodes

Field Diodes and Rectification
The rotor field must be energized (excited) to enable the alternator
to operate.
It could be permanent magnet or electro-magnet
The current can be obtained from the battery for electro-magnet or
from the alternator itself due to the permanent magnet.
When current from the battery is used, the alternator is referred to
being externally excited.
While, when the current from the alternator stator is used, then the
alternator is self excited.
Self excited alternators use three extra diodes, making nine diodes
in all. These three diodes are known as field diodes or excited
diodes, and other six diodes are known as power diodes.
Field diodes are used to rectify the un-rectified AC voltage of the
power diodes.
Field Diodes
When a star-wound startor is used, the addition of the voltage at the neutral point of the
star is, in theory 0 volt.
But, in practice due to the slight inaccuracies in the construction of the stator and rotor, a
potential voltage develop at this point.
This potential is known as the third harmonic.
Its frequency is 3 times the fundamental frequency of the phase windings.
By employing two extra diodes, one positive and one negative connected to the
star point, the energy can be collected. Photo
This can increase the power output of an alternator up to 15%.
Alternator Performance
Field Diodes: increase alternator performance by 10%

Third Harmony: Increases alternator performance by
5-15%
Charging System-Voltage Regulator

Voltage Regulators
Alternators are fitted with a regulator to control their voltage.
A voltage regulator is needed because the alternator produces a rising
voltage.
The voltage is related to alternator speed
the faster the rotor spins, the higher the voltage.
Regulation is achieved by varying the strength of the rotor of the field.
Transistor and integrated circuit are the voltage regulator of the
alternator.
Vehicle Electrical Loads on Alternator

The loads placed on an alternator can be considered
as :
Continuous load: used continuously and the charging
system will have to keep up.
Prolonged load: keep it on until turn off.
Intermittent load: used infrequently. Such as the heated
rear windows and seat heaters.
The charging system of a modern vehicle has to cope

with high demands under many varied conditions.
Output that may be required power used by the individual
components and add this total to power required to
charge battery
The current draw about 0.5A at 14 and 28V.
Continuous Load
Power
(W)
Current
(amp)
14V
28V
30
2.0
1.0
Fuel Injection
70
5.0
2.5
Fuel Pump
70
5.0
2.5
Instruments
10
1.0
0.5
Total
180
13.0
6.5
Side and tail lights
30
2.0
1.0
Number plate lights
10
1.0
0.5
Headlight mean beam
200
15.0
7.0
Headlight dip beam
160
12.0
6.0
Dashboard light
25
2.0
1.0
Radio/CD
15
1.0
0.5
Total
260
19.5
9.5
Heater
50
3.5
2.0
Indicator
50
3.5
2.0
Brake light
40
3.0
1.5
Front Wippers
80
6.0
3.0
Horn
40
3.5
1.5
1440
106
53.5
and etc
1700
Charging system regulation

A vehicles electrical system and battery must be protected from
unstable or excessive charging system voltage.
Computer sensitive system is the best one to control the alternator
output for both in charging and vehicle load demand
.
Adjust the alternator for varying the load demands
While at the same time keeping the battery fully charged.
It is noted that
Battery will gradually run down over time if the charging
current is low
While, the vehicle electrical circuit or the battery
component will be damaged if the charging current is
higher than needed.
A figure of 14.2 0.2 V is used for all 12 V battery charging
system
Charging circuits
The charging circuit is one of the simplest on the vehicle.
The main output is connected to the battery via a suitable sized
cable
The warning light is connected to an ignition supply on one side and
to the alternator terminal at the other.
The output of the alternator is often connected to the starter
main supply simply for the convenience of wiring.
If the wire are kept as short as possible, reduce the voltage
drop across the main supply wire.
Testing procedure
Connecting voltmeter across the battery and an ammeter in series
Battery must be 70% charge (i.e., 8.4 volt)
Regulated voltage (ammeter reading 10A or less) :14.2 0.2 Volt
Circuit voltage drop 0.5V maximum.
Charge balance calculation.
The charge balance or energy balance of a charging system is used to
ensure that the alternator can cope with all the demands placed on it
and still charge the battery.
Typical voltage regulator voltage range.
General Motors CS generator.

Notice the use of zener diodes in the rectifier to help control any high-voltage
surges that could affect delicate computer circuits.
If a high-voltage surge does occur, the zener diode(s) will be reverse biased and
the potentially harmful voltage will be safely conducted to ground.
Voltage must be preset at the L terminal to allow the generator to start producing
current.
The alternator field (rotor) current is controlled by the computer.

SMEC stands for single module engine controller.

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International Islamic University Malaysia

Department of Mechanical Engineering, Kulliyyah

Automotive Charging System

The main function of automobile charging system is to

Automobile charging system generally generates a voltage

The main components of the charging system is the

The alternator generates AC but must

The (+ive) is anode and (- ive) is cathode.

Three phase AC are passed of an alternator to a DC

Alternator and Charging Circuits

Full-wave rectification in a delta wound is accomplished with the same

- As the magnetic field, created in the rotor, cuts across the

windings of the stator, a current is induced.

A star connection can be thought of as a type of series connection of the phases

A delta connection can be thought of as a type of parallel circuit.

where, V =output voltage, Vp=phase voltage, I=output current, Ip=phase

Heavy vehicle are used the delta connected/winding alternator

n = alternator speed in rpm

Charging System-Inducing EMF (Voltage)

Charging System Field Diodes

Field Diodes: increase alternator performance by 10%

Charging System-Voltage Regulator

Vehicle Electrical Loads on Alternator

The charging system of a modern vehicle has to cope

Side and tail lights

Number plate lights

Headlight mean beam

Headlight dip beam

Charging system regulation

Typical voltage regulator voltage range.

General Motors CS generator.

The alternator field (rotor) current is controlled by the computer.

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