CHARGING SYSTEM

INTRODUCTION

In the charging system electronics devices such as diodes for rectification of current in
alternator zener diode and transistor for circuit opening and closing in transistorised
regulators are use. In this unit, the construction and function of diodes and transistor,
the purpose of the charging system, the component parts of alternators, the generating
principles of alternator, the charging system service and repair are thoroughly
discussed.

Semi conductors

Semi-conductors are elements that are neither good conductors nor good insulators.
Because of the atomic structure, the resistance of such materials can be made to very
widely with the application of small quantities of impurities. Because of this
characteristics, semi conducts are widely used in the manufacturer of device as diodes
and transistors.

The following elements are used in the manufacturer of semi-conductor device such
as diodes and transistors by doping process with germanium and silicon.

No Element Valance Election

1 Antimony (S6) 5
2 Arsenic (AS) 5
3 Phosphorous (P) 5
4 Germanium (Ge) 4
5 Silicon (Si) 4
6 Aluminium (Ai) 3
7 Boron (B) 3
8 Gallium (Ga) 3
9 Indium (In) 3

N- Type and p- type doping

The elements used for doping, generally have an electron valence of either five or
three, as a result, the doped smi conductors has either an excess or shortage of
electrons in the covalent bond structures. A semi- conductor with electrons excess is
the N- type while p- type has a shortage of electrons.

N- type semi- conductor

The doping elements Asnic, Antimony and Phosphorus have a valance of five.
For each outer most ring. In a covalent bond with Germanium (Ge) and silicon (si)
atoms having four valence electrons, each impurity atom provides an extra electron,
which is a free charge not needed for the covalent bond.

Si Si Si

Si Si Si Free electron

Si Si Si

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 P- type semi- conductors

The dipping elements

Hole charge Aluminium, Born,
Si Si Si Gallium, and Indium
have a valence of
three electrons in the
outer most ring. In a
Si Al Si
covalent bond with
germanium (Ge) or
silken (si) atoms,
there are seven
Si Si Si electrons instead of
eight for each bond
the one missing electron in such a covalent bond can be considered as a free positive
charge called hole charge.

The Depletion region

P-N junction

P-Type P N N-Type
germanium germanium

When the P-N junction is formed, free electron diffuses across the junction to
combine with holes that are near the junction in the "P" section. At the same time
holes from the "P" section diffuse the junction to combine with free electron's that are
with in the N-Section near the junction. As a result of these combinations the atoms
near the junction of each section becomes ionised. Since this action reduces the
number of N-Sections and P-Section holes, these are where the ionisation process
takes place is called a depletion region.

Potential Barrier

Because of the electron-hole combination within the depletion region, atoms with in
the "P" section gain electrons becomes negatively charged while atoms within the N-
section lose electrons and becomes positively charged. This condition creates. A small
voltage across the junction called potential barrier because of polarity of the potential
barrier, there is no further significant diffusion of electrons from the N-Section and
holes from the P-Section.
The schematic symbol for diode

(+) (-)

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Characteristics of diodes

When the N material is connected to the negative terminal of the battery, a very high
resistance is formed at the P-N junction. This state prevents a current flow through the
circuit.

But when the connection is reversed, they battery negative to the N-material and the
battery positive to the P-material this state will allow current to flow

Depletion
region

Negative - + Positive ion

ion
- +
- +
C
Potential
barrier

E
Transistors
They are semi conductor devices containing three semi-conductor regions each of
which has an external connection points. These terminals are called base(B),
collector(C) and emitter(E). PNP type transistor has one negative region sandwiched
between two positive regions. NPN has one positive region sandwiched between two
negative regions they are used for switching function.

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5.3 Purpose of the charging system
The charging system has two jobs. These are
a) To put back in to the battery the current used to start the engine
b) To handle the load of the lights, ignition, radio and other electrical and
electronic equipment's while the engine is running

c) The charging system includes the alternator regulator and battery with
connecting wires.
5.4 Generating principles of alternating current generator

An electrical generator is a machine that converts mechanical energy in to electrical

energy. This energy conversion is based on the principle of the production of
dynamically induced electromotive force. Whenever a conductor cuts magnetic lines
of force dynamically induced EMF is produced in it according to faradays low of
electromagnetic induction This EMF will cause a current to flow if the conductor
circuit is closed.
Hence the basic essential parts of an electrical generator are:-

a) A magnetic field
b) Conductors which can move so as cut the flux.
When the electricity by a coil is
supplied through slip rings and brushes,
the amount of current flowing to the
lamp will change and at the same time
so will direction of flow.

As the coil rotates the current generated

on the first half of the turn will be
supplied from the brush on side pass
through the lamp then retain to the
brush on side B. On the second half turn
the current will be reversed. In this
fashion, the alternating current generator supplies the current generated by the coil in
a magnetic field.

The following figure illustrates

Rectification
The electrical components of an
automobile required direct current for
operation and battery needs direct current
for charging. The alternator produces three
phase alternating current but the charging
system of the automobile can not use this
electricity unless it is converted to direct
current. There fore the alternating current
is rectified in to direct current by
diodes which are built in the alternator
circuit.

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Thus we can see current from each coil to the diodes is constantly changing
direction in the three leads so the direction of current from the diodes does not
charge but forms a circuit with varying polarity.

The main components of the alternator and their functions

Rotor

The rotor is composed of two cores, a field coil slip rings and rotor shaft. The field
coil is wound in the same direction as rotation and each end of the coil is
Connected to a slip ring. The two cores are installed at each end of the coil so as to
enclose the field coil. Magnetic flux is produced as current flows through the coil and
one pole becomes the north pole and the other the south pole. The slip rings are made
of metal with a highly brush contacting surface and they are insulated from the rotor
shaft.

Stator

The stator is composed of stator coil, and is secured to the front and rear ends of the
frame. The stator core consists of thin layers of steel plating. The inner side has slots
in which there are three independent stator coils. The stator core acts as a passage
which allows the flux effectively cross to the stator coil from the rotor core.

Diodes

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Three positive diodes and three negative diodes are contained in their respective
diode holders. The current generated by the alternator is supplied from the positive
side diode holder so it is insulated from the end frames.

During rectification the diodes become hot so the diode holders act to radiate this heat
so the diode holders act to radiate this heat away and prevent the diodes from
overheating.

In addition, there are also brushes which supply current to the rotor for the production
of magnetic flux the bearings which allow the rotor to rotate smoothly and a fun to
cool the rotor, stator and diodes. All of these components are hold by front and rear
frames.

Regulators for alternators

Several types of alternator regulators that are mounted outside the alternator have
been used. The regulator limits alternator voltage by controlling the amount of current
flowing in the alternator field or the regulator reduces the field current. This prevents
excessive voltage.

A. One point type regulator

In this regulator a resistor (R) is connected in series with the field coil (F) of the rotor.
This resistance is by passed by the points while the engine is running at low speed.
Because the magnetic coil is weak and the points remain closed when the voltage of
the alternator is strong the points open and current passed through the resistor and the
field coil current is reduced and the voltage of the alternator reduces and points close.
In this manner the voltage is stabilized by this type of regulator.

However, one point type regulator is not used very often in present day automobiles
be cause of the following disadvantage.

a) There is great fluctuation of voltage at low speed when the points are
opened and closed
b) A large resistance will cause more sparking when the points are opens
resulting shorter life of the points.

B. Two point type regulator

The characteristic of the two point type regulator is that it has both low speed and
high speed operating ranges.

At low speed, the moving point opens and closes the low speed point (P1) in the same
manner as the point make and break contact with the high speed point and field
current ceases to flow and the voltage out put of alternator decrease as a result the
moving point closes with P1 and this cycle is repeated.

But the disadvantage of this type of regulator is the voltage drop due to the hysterics
effect when changing from the high speed side to low speed side.

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Nevertheless. Compared to the one point type, the resistance can be made smaller so
there is less sparking so there is a longer life of the points.

C. Voltage Relay (Charge lamp relay)

A Charging system employs a two element combination accurate voltage regulation.

This is because, the voltage regulator operates in accordance with the voltage
generated by the alternator. If there were no voltage relay, there would occur a drop in
voltage in the magnetic coil because the voltage is applied to a long circuit via the
ignition switch. A reduction of voltage would cause a proportionate decrease in
magnetic force of magnetic coil so the moving points would not pulled sufficiently. As
a result alternator voltage would raise to high.

Characteristics of the regulators

For the point type regulators, there are various reasons why voltage fluctuates. But the
primary causes are due to its hysterics and temperature characteristics.

A. The hysterics characteristics

The lowering of voltage when the moving point change from high speed side to the
low speed point called hysteretic effect
causes to remain a residual magnetism
from the high speed operation in the coil
core and continue to pull the moving
point for a short time. This phenomena
cause to the alternator out put to decline.
There fore no attempt should be made to
adjust the regulator when the voltage is
dropping due to this effect. A 12 volt
system will drop from 0.5 to a volt.

B. The temperature characteristics

The magnetic coil of the voltage regulator employs copper wiring. It temperature of
this wire rises, the resistance increased and there will be a reduction of force
(electromagnetic force) of the magnetic coil this results a higher alternator out put
voltage to prevent such arise in voltage, the regulator utilizes either a resistor or bi-
metal element for temperature compensation, but some use both.

The resistor reduces the over all resistance

in accordance with the temperature
fluctuation as a result strong
electromagnetic force is developed and the
contact point will be pulled sufficiently.

The bi-metal element is used together with

a spring which supports the moving point.

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The bi-metal element reduces the spring tension as the temperature rise. There fore the
contact point will be easily opened to prevent the raise of alternator out put voltage.

Operation of a regulator with voltage relay

a. When the ignition switch is on engine stepped.

When the ignition switch is turned on field current from the battery flows to the rotor
and excites the rotor coil. At the same time, battery current also flows to the charge
warning lamp and the lamp comes on.

b. Engine operation- (low speed to middle)

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After the engine is started and the rotor is turning. Voltage is generated in the stator
coil, and neutral voltage is applied to the voltage relay so the charge warning lamp
goes out. At the same time; out put voltage is acting on the voltage regulator. Field
current to the rotor is controlled in accordance with the out put voltage acting on the
voltage regulator. Thus depending on the condition of point PL0, the field current
either passes through or does not pass through the resistor (R)

C. Engine operating (Middle speed to high speed)

As engine RPM increases, the voltage generated by the stator coil rises and the pulling
force of the magnetic coil becomes stronger with a stronger pulling force, field current
to the rotor will flow intermittently. In other words moving point PL 0 of the voltage
regulator intermittently make contact with point PL2.

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 IC Regulator

The integrated circuit regulator is compact and light weight and excellent
reliability due to its lack of mechanical points compared with the point type, it
has the following features.

Advantage

1. A narrower out put voltage range and little variation with time
2. Good resistance to vibration and high durability due to lack of
moving parts

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 3. Voltage out put becomes lower as its temperature rises, hence
proper charging of the battery can be performed.
Disadvantage

Susceptible to unusually high voltage and temperatures.

Operating principles of IC regulator

As in the illustration show, when the out put voltage at terminal B is low, the
battery voltage is applied to the base of Tr1 through resistor R and Tr1 turns on
at the same time, field current to the
rotor flows from B-rotor coil.

When the out put voltage at terminal

B is high a higher voltage is applied
to the zener diod (ZD) and when
this voltage reaches the zener
voltages, the zenerdiod becomes
conductive. Accordingly, as Tr2 turns
on Tr1 turns off. This interrupts the
field current. Regulating the out put
voltage.

Alternator checks and services

Before disassembling the alternator, noise test certainly test, are performed to
help us when each components are inspected during the disassembling stage

Rotor
A. Rotor test
Check that three is continuity
between the slip rings if there is
no continuity , replace

B Inspect rotor for ground

Check for
continuity between
the slip ring & rotor.
If there is continuity
replace the rotor.

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C Inspect slip rings
Check the
slip ring
diameter if
it is less
than the
minimum
limit,
replace
the rotor.

Stator;

a) Inspect stator for open circuit there must be continuity between

coil leads if not replace stator
b) Test stator for ground
Check if there is no continuity between the coil leads and the stator core. If
there is continuity, replace the stator

Rectifiers

a) Inspect positive rectifiers

Using ohmmeter connect the one test probe to each rectifier
terminal, and the other to positive
Reverse the polarity of the probe
Check that the other shows continuity and the other doesn't
If continuity is not as specified replace the holder

b) Inspect negative rectifier- Using an ohmmeter connect the test

probe to each rectifier terminal and the other to the negative
terminal
Reverse the polarity
Check that one shows continuity and the other doesn't
If it is not as specified replace the rectifier holder

5.10 Regulator checks and service

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 a) Point surface inspection for burning if damaged, replace the regulator
b) Inspect resistance between terminals

* Between IG and F
At rest 0
Pulled in refer the specified resistance it must be about 10
Between L and E
At rest 0

Pulled in refer to the specification of the regulator

Between B and E

At rest- Infinity

Pulled in refer the specification

Between B and L
At rest infinity
Pulled in approximately O

Between N and E

The resistance must be checked with the specification

Adjustment

a. Adjust the voltage regulator by bending the regulator adjusting

arm
b. Adjust the voltage rely by bending the relay adjusting arm

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