CHARGING CIRCUIT
This is a circuit responsible for converting mechanical energy into electrical
energy. On modern vehicles, the generation of energy is done by using an
Alternator which isis the main components of the charging system. It is
usually driven by the engine fan belt.
The main purpose of the circuit is to carry out the following when the engine
is running:-
To supply energy to all the circuits within the electrical system.
To recharge the battery so that it can be re – energized for the next
cranking
CHARGING SYSTEM REQUIREMENT
The system should be able to meet the following requirements in operation:-
To supply the current demands to meet some or all system loads.
To supply a suitable charge current levels needed for recharging the
battery
To be able to supply the required system current even at idle speed
Maintain a constant voltage under all conditions
Should be reliable, quiet, resistant to interference and contamination
Has efficient power output to components weight ratio
Should have some indication of correct operation (i.e Warming light or
ammeter)
CONSTRUCTION OF THE ALTERNATOR
The alternator which is a key component of the charging circuit is made of
the following parts: -
BRUSHES: They are made of carbon and allow a small electric current to pass
through the slip rings to the field windings
SLIP RINGS: They allow an electric current pass through to the rotor
ROTOR AND WINDINGS: It is made of cast iron and is a magnetic rotor. The
most common type of rotor is the Claw pole rotor.
PULLEY : It transfers the engine drive to the rotor
STATOR: The stator is usually induced with electricity by the rotating
magnetism of the rotor. It produces a three phase alternating current. It is
connected either in Star or Delta arrangement
RECTIFIER: This is the device which converts the generated alternating
current into direct current
RGULATOR: It is responsible for the control of the field coilwinding current
and thereby controlling the output voltage of the alternator.
OPERATION
The field coil are the rotating part called the rotor and are fed with current
through brushes, Around the field coils are some soft iron magnetic pole
pieces which concentrates the magnetic flux for maximum effect. As the
rotor rotates between the stator coil, there is an output voltage as its
magnetic field changes due to the rotation of the rotor field, The stator coils
carry the large generated alternating current (AC) which is later fed to the
diode pack for conversion to direct current (DC). The process of conversion
of AC into DC is known as Rectification. The DC is supplied to the electrical
system for energizing the electrical circuits and also re - charge the battery
for the next cranking action. Theoretically, a charging voltage of 14 Volts and
28 Volts is considered as normal on 12 Volts and 24 Volts electrical systems
respectively.
RECTIFICATION OF ALTERNATING (AC) CURRENT TO DIRECT CURRENT (DC)
The process is facilitated by use of Silicon Diodes. Diode are considered to be
one way electric current switches. The rectifier pack consists of six main
diodes and three smaller ones viz: three positive diodes, three negative
diodes and extra three positive field or excitation diodes. The main diodes
are responsible for the rectification process while the smaller diodes only
supply a small current back to the field windings in the rotor for excitation. A
heat sink is incorporated in the pack to prevent thermal damage.
REGULATION OF OUTPUT VOLTAGE
To prevent the battery from being overcharged, an accurate voltage control
is vital. A Voltage Regulator is incorporated in the circuit to regulate the field
output voltage and thus limiting the field strength and the maximum current
an alternator can produce. Regulator can either be mechanical or electronic.
Electronic regulators have become more popular than the mechanical type
because of operational efficiency and convenience. The key to electronic
regulation is the incorporation of the Zener Diode
CHARGE WARNING LIGHT
It is usually connected in the alternator circuit to indicate both supply of the
initial excitation current to the field windings for electromagnetism effects
and as a circuit warning in an event of malfunction in the circuit. The charge
warning light is extinguished (or automatically switches off) when the
alternator produces an output voltage from the field diodes resulting in the
bulbs taking same voltage from both sides bringing the potential difference
across the bulb to 0 Volts
COMMON SYSTEM FAULTS AND POSSIBLE CAUSES
N DEFECT POSSIBLE CAUSE
O
A No Charging 1) Loose connection
2) Sticking m Worn out brushes
3) Worn out slip rings
4) Open charging circuit
5) Open circuit in stator windings
6) Open rotor or (field) circuit
7i) Blown up fuse wire in regulation
8) Slipping fan belt
9) Burnt commutator (Dynamo)
10) Open rectifiers
B Low or un steady 1) High resistance in charging circuit
charge 2) Poor earthing between body and engine
block
3) As in ‘A’ except 7 and 10
C Low charging rate 1) High resistance in the charging circuit
2) Shorted or open rectifier
3) Low regulator setting
4) Grounded stator winding
D Overcharging 1) Voltage regulator set too high
2) Sticking regulator contacts
3) Open regulator voltage winding
4) Loose regulator ground connection
E Regulator troubles 1) Oxidised contacts
2) Burned contacts
3) Sticking contacts
4) Burnt Voltage windings
5) Defective transistor regulator
6 Noisy operation 1) Loose mounting
2) Worn bearings
3) Worn belt
4) Open or shorted rectifiers
Open or shorted stator winding
STARTER MOTOR CIRCUIT
This is a circuit responsible for converting electrical energy into mechanical
energy. On modern vehicles, the initial cranking of the engine to trigger the
operating strokes is achieved from mechanical force created by a Starter
motor which is conveniently fitted near the flywheel.
The purpose of the circuit is to carry out the following:-
To convert the electrical energy into a rotary force of a motor to rotate
(crank) the engine so that it can run.
To provide a mechanism for engagement and disengagement of rotary
force to and from the flywheel for smooth operation
The main reason for cranking an internal combustion is to enable the
reciprocating motion of the pistons which is a requirement for the induction
and compression of the air or mixture before combustion. The products of
combustion have to be expelled from the cylinders in readiness for the next
cycle. The ultimate objective is to enable the engine continue running on its
own after the cranking action.
REQUIREMENTS OF THE STARTER SYSTEM
A starter circuit should be able to meet the following requirements in order
to be considered suitable for the functionality.
Should conform with the system rated voltage of the starting system
(12or 24V)
Should be able to start the engine at lower temperatures (Good
starting limit temperature)
Should have sufficient torque to overcome all the engine resistances
Should conform with the battery characteristics
Should have minimal voltage drop between the battery and stater
motor
The Staring system should therefore be designed to provide a good service
at low maintenance and should be continuously be readily available to
operate. It should be robust to withstand starting forces, vibrations, corrosion
and temperature cycle and should be of a reasonable size and weight.
CONSTRUCTION FEATURES OF THE STARTER MOTOR
The starter assembly has the following features: -
1. ARMATURE: It is a rotating component with windings which become
magnetized and cause the motor to turn because the magnetism of the
armature is repelled by the main field.
2. COMMUTATOR: These are segments of copper which allows the passage of
current to the appropriate winding of the armature.
3. CARBON BRUSHES: These are copper/carbon mix brushes which carry the
current to the commutator
4. FIELD COILS (POLES) This is the main magnetic field of windings made of
permanent magnets. They may be made of heavy duty windings.
5. PINION: It is a small gear with a ratio of about 10:1 compared to the ring
gear.
6. SOLENOID: It is an electromagnetic switch which connects heavy current
from the battery to the motor.
7. STARTER CONTACTS: These are thick copper contacts located inside the
solenoid which connects the battery current to the motor for operation.
8. STARTER CLUTCH (BENDIX): This is a mechanism which levers the pinion
into mesh with a flywheel ring gear to disengage when the solenoid is
switched off.
9. CASING OR HOUSING: It is a cast that harnesses the internal the armature
and the field poles (windings)
10.BEARINGS: The are located at both ends of the armature to support it
and reduce rotational friction as the shaft spins
OPERATION
When the solenoid is energized by the current from the ignition switch at
cranking, the windings create a magnetic field inside which pulls the plunger
carrying a copper disc contact. As the plunger moves further it connects the
disc a pair of starter contacts to enable a heavy current flowfrom the battery
directly into the motor. As the plunger moves it activates the yoke to lever
the pinion into engagement with the ring gear.
Current is conducted into the armature through the brushes and the
commutator to create a magnetic field. The magnetic effects of attraction
and repulsion of fect.poles causes the rotation of the armature (Flemming’s
Rule) to facilitate engine cranking.
TYPES OF STARTER MOTORS
Starter motors can be classified according to the engagement arrangement
implored in operation. There are two common types of engagements namely:
Pre – engaged and Inertia types
PRE – ENGAGED ARRANGEMENT: It is also referred to as the Bendix type. It
has a clutch and pinion assembly which can be levered by the yoke for
engagement into the ring gear. The pinion engages the gear before the
rotation of the motor when the solenoid is energized. It remains in
engagement as long as the solenoid is energized. It disengages and retains
its position as soon as the current is cut.
INERTIA TYPE: This is an overrunning type of clutch. The clutch and pinion
assembly is in constant mess with the flywheel ring gear. It rotates when the
relay fitted between the battery and the motor is energized to permit heavy
current flow. As soon as the engine starts, the clutch assembly overruns and
consequently causes free wheeling effect on the pinionautomatically and
stopping its turning effect.
TYPES OF STARTER SWITCHES
There are several methods of connecting the heavy current flow from the
battery to the motor. The following are the types found on most vehicles and
machine:
a) Solenoid Switch:It is also referred to as Starter relay which uses electric
current to energise the winding that pulls the plunger to cause the copper
disc connect the contacts and facilitate current flow.
b) Manual Switch: It is also referred to as manual switch. It uses a
mechanical plunger to make contact between the battery and starter motor
c)Natural Safety Switch: This type of switch is commonly incorporated in the
Automatic transmission system. It is usually connected in series with the
starter switch to prevent the cranking of the engine unless the shift control is
in neutral or park.
COMMON SYSTEM FAULTS AND POSSIBLE CAUSES
N DEFECT POSSIBLE CAUSE
O
A Starte motor does not 1) Discharged or defective battery
crank 2) High resistance in the starter motor
3) High resistance in the starter control circuit
4) Open circuit in starter switch or solenoid
5) Open or short circuited armature
6) Open or short circuited field winding
7i) Wrong or worn or starter motor bushes
8) Broken or weak brush springs
9) Tight armature shaft bearing or seized
bearings
10) Defective or jammed starter clutch or
pinion in
flywheel
11) Hydraulic lock due to interference with
engine
piston of crankshaft movement
12) Excessive friction in engine
B Low starter motor 1) To high viscosity of engine oil
cranking speed 2) Same cause as in 1,2,3,7,8,9,10,11 and 12
C Starter motor spinning 1) Defective drive pinion
but fails to crank. 2) Defective clutch mechanism
3) Misaligned flywheel / pinion gear
4) Defective solenoid switch contacts
D Starter motor failures to 1) Defective starter clutch and drive pinion
disengage. assembly
2) Broken return spring
3) Slipping bendix clutch
4) Misaligned pinion gear
5) Broken pinion gear
6) Jammed pinion gear
ELECTRICAL CIRCUIT AND COMPONENTS TROUBLE
SHOOTING
In practice, fault finding on circuits and components involves circuit and
component testing with the help of the measuring instruments. Electric
current is not visible however, the effects of current flow can form a basis of
its intensity and detection.
TESTING OF CIRCUITS AND COMPONENTS
One of the methods of testing current flow is to measure its resistance. If we
are able to get the resistance you expect in a particular circuit and on all its
components, it is an indication that all the components are probably working
correctly. The following are the tests which can be done to ascertain their
serviceability
1. OPEN CIRCUIT TEST: This is a fault finding test done on the wiring to
establish a breakage that prevents current flow. The circuit will have no
continuity and give a maximum or an infinity resistance value on a meter. An
open circuit will not allow current flow at all. It is said to be ‘dead’.
2. SHORT CIRCUIT TEST: This is a fault finding test done on the wiring to
establish a leakage of current flow due to poor or damaged insulation
resulting in current grounding as it touched the body before passing through
its normal path. The circuit will give a lower resistance value on a meter. It
may occur within a component. A shorted circuit will not allow current to
complete a designated circuit but will leak to earth..
3. CONTINUITY TEST: This is a fault finding test done on the wiring or
component to determine if there is an open circuit. It is done by
disconnecting or isolation of the component from the circuit. If there is a
resistance value, then there continuity in the circuit. On the contrary, if there
is no resistance, an open circuit can be suspected.
TEST INTERPRETATION
If the resistance is so high and un measurable (infinity) on the meter, an
Open circuit is suspected. Zero resistance could mean that a bare wire is
touching the body and grounding the current. A resistance value in the
circuit indicates that there is continuity in the circuit. Owing to the numerous
test to be done on circuits and components , knowledge about the use of
multi meters is vital and necessary for a modern mechanic
ELECTRICAL SYSTEM - CLASS EXERCISE
1. With the use of the Electrical Symbols provided draw three simple
circuits with components in the following connections:-
(a) Series Connection
(b) Parallel Connection
(c) Series Parallel Connection
2. Using block diagram of a Battery, draw a simple diagram showing
Connection of two 12 Volt batteries in the following systems:-
(a) 24 Volts Electrical system
(b)12 Volts system with a long battery ampere hour
ELECTRICAL SYSTEM - CLASS EXERCISE
1. With the use of the Electrical Symbols provided draw three simple
circuits with components in the following connections:-
(a) Series Connection
(b) Parallel Connection
(c) Series Parallel Connection
2. Using block diagram of a Battery, draw a simple diagram showing
Connection of two 12 Volt batteries in the following systems:-
(a) 24 Volts Electrical system
(b) 12 Volts system with a long battery ampere hour
ELECTRICAL SYSTEM - CLASS EXERCISE
1. With the use of the Electrical Symbols provided draw three simple
circuits with components in the following connections:-
(a) Series Connection
(b) Parallel Connection
(c) Series Parallel Connection
2. Using block diagram of a Battery, draw a simple diagram showing
Connection of two 12 Volt batteries in the following systems:-
(a) 24 Volts Electrical system
(b) 12 Volts system with a long battery ampere hour
