Alternators & Generators

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The Automotive Electrical System - Alternators

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The electrical system in any modern vehicle is made up of three primary components; the 12 volt battery, the voltage regulator and the alternator. An alternator is an electro-mechanical generator that transforms mechanical power into electrical energy. The mechanical power comes from the engine itself and is driven by the crankshaft. The engines crankshaft powers several auxiliary systems under the hood, all of which are driven by the serpentine belt and a number of pulleys.
In the automotive environment, the alternator is used to recharge the vehicles battery (DC), which in turn powers the vehicles electronics. Since alternators output AC, so a diode rectifier is used to convert the AC into DC and a voltage regulator is used to distribute the power and control the electrical output going to the battery. The battery is the vehicles primary source of DC power, so when the engine is running, the alternator is continually charging the battery to keep if from dying.

An alternator works by turning the up and down movement of the engines pistons into circular motion. The alternator is connected to the crankshaft through a series of pullies and belts. The alternator pulley is connected to the primary belt system, and thus the crankshaft, by the alternator belt. As the pulley spins with the crankshaft, a rotor spins inside the alternator. As the rotor spins, it passes three stationary copper windings on the stator ring. This produces an AC current; since there are three copper windings on the stator ring, this AC generation is referred to as a 3-Phase current. The current is fed from the stator through the stator leads into a series of diodes, which converts the AC into DC.

It should make sense then, that the faster the crankshaft spins (the higher the engine RPM's), the more power the alternator will produce and the faster the car battery will recharge.
The most common reason alternators fail is due to the alternator bearing overheating and getting damaged. When the bearing fails, the rotor can't spin efficiently enough to generate a charge, thus causing the vehicles electrical system to fail. Another cause, although less common, is for the alternator belt (serpentine belt) to get worn out. If the belt gets worn out, it will slip when it tries to rotate the alternator rotor, thus failing to generate a current. Both of these problems are fixable with parts, although it is sometimes cheaper to replace the alternator than it is to paying the labor rate to replace the alternator bearing.
 


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