Automotive Alternator Research Articles

차량용 발전기 효율 향상을 위한 MOSFET 정류기 구현

차량용 발전기 효율 향상을 위한 MOSFET 정류기 구현

Modeling the Time-Varying Advantages of a Remanufactured Product: Is “Reman” Better Than “Brand New”?1

In order for remanufacturers to succeed in the market, it is important for them to be capable of ensuring in advance that a product is suitable for remanufacturing and that a remanufactured product will provide greater economic and environmental value than a brand-new product. This paper provides an approach to estimate the economic and environmental advantages of a remanufactured product. Focusing on the fact that advantages are greatly influenced by the nature of a product (i.e., its design and lifetime characteristics) as well as the timing of the remanufacturing, this paper proposes a model for assessing the time-varying advantages of remanufacturing a given product. The model provides an objective, quantitative method to compare a remanufactured product with an equivalent brand-new version of the product. Focus is placed on three perspectives: unit production cost, environmental impact, and net profit. By providing a multidimensional assessment tool for measuring product remanufacturability, the model is expected to assist remanufacturers make informed and effective decisions concerning product planning. It also helps marketing activities by supporting an effective sustainability communication with customers. Two versions of the model are presented, each of which targets a specific product type: (1) a product with only physical deterioration and (2) a product with both physical deterioration and technological obsolescence. Each version of the model is illustrated by utilizing an automotive alternator and a desktop computer, respectively.

APPLICATION OF CLAW-POLE SYNCHRONOUS GENERATOR IN SMALL WIND TURBINES

Small wind turbines have been in existence for several years but it seems they are not used where they are needed the most-distant off grid communities in developing countries. Cost and maintenance have been attributed to be reasons for this. One of its expensive constituents is its generator. The automotive alternator is considered as a cheaper alternative for generators in small wind turbines. In this paper, a detailed mathematical model for a 3-phase, 4 kW and 42 V claw pole alternator average electrical equivalent circuits will be presented along with the DC/DC converter based architectures for dual-voltage systems. The performance of the 42V claw pole alternator with the interleaved six-phase buck dc-to-dc converter system is modeled using Simulink software to assess the effectiveness of the model and its transient behavior.

Устройство встроенного контроля ременной передачи автомобильного генератора

Устройство встроенного контроля ременной передачи автомобильного генератора

Экспериментальное установление зависимости напряжения автомобильного генератора от натяжения приводного ремня

Экспериментальное установление зависимости напряжения автомобильного генератора от натяжения приводного ремня

Analysis and Optimization for the Production Process of an Automotive Alternator Using FEM and Experiments

This paper presents the analysis and the optimization of the process parameters for an innovative and more efficient production system for claw pole alternators intended for automotive application. The authors, after a preliminary study about forces, material properties and geometrical specifics to achieve, set out a first set of parameters to realize an 8-pole rotor. After that, it was possible to layout each step of the forging process in a FE model and observe the geometrical properties of the final rotor. Once reached a good comprehension of the whole process by preliminary studies, experiments were conducted with the effective material currently employed to build the claw pole and other information were collected to refine the finite element model. By comparing the results between the FEM and experiments, it was possible to build a realistic model, which allowed adjusting the process in short time in order to make the final product meet all the required geometrical specifics and pass the electrical tests.

The Impact of Automotive Product Remanufacturing on Environmental Performance

Remanufacturing, as an emerging industry with great potential, presents an excellent product end-of-life (EOL) alternative to extend the number of product life cycle from one to multiple. However, the procedure to quantify the environmental consequences of the complex life cycle of a remanufactured product is still not yet available. In this regard, a modified cumulative energy consumption method is proposed to effectively assess the relative environmental benefit of a remanufactured product and support the decisions on improving product design and EOL recovery system. The applicability and importance of the proposed methodology has been demonstrated by the two case studies, namely, automotive alternators and engine blocks.

The Use of Infrared Thermography for Maintenance Purposes in the Production Process of Components for Automotive Alternators

This work reports an investigation concerning the employment of infrared thermography in the production environment of claw pole alternators, aimed for early detection of anomalies during the stamping stage at the press. The investigated process consists of a number of steps, starting from a raw workpiece in the form of a star, sheared from a low carbon steel plate, is brought to its final shape through bending and coining operations, using a progressive die. The process is characterized by a high production rate since the component is destined for the automobile market, therefore the controlling of both the die conditions as well as the mechanical press is crucial in order to reduce unexpected stops of the process.After having analysed each production stage, a series of experimental tests have been carried out and a series of thermal snapshots were taken during the normal production run and analyzed in order to detect any process signature which were capable of giving information concerning the process conditions. An FEM model has also been developed for each step of the process in order to characterize the material flow and, in addition, the thermal field related to the transformation of the mechanical energy into heat, due to plastic deformation of the material and frictional effects. Correlations between the geometry resulting from material flow and thermal maps detected in the production environment have allowed to address of the maintenance activity in order to eliminate defects which can affect significantly the functionality of the product as well as the die life.

Produção e captação de energia elétrica limpa através de adaptação de bicicletas ergométricas

O crescimento da sociedade e o desenvolvimento de novas tecnologias implicaram no aumento da produção de equipamentos eletrônicos associado ao consumo de energia. Com a dominância da participação das fontes não renováveis na oferta mundial energética, presentes em quantidades limitadas, a sociedade busca por fontes alternativas de baixo custo e alta eficiência, como soluções para diminuição do impacto ambiental causado pelo aumento da poluição a nível mundial. A busca por energias renováveis de uso sustentável é a grande meta para o desenvolvimento de tecnologia mundial, preservando a Natureza. O presente trabalho apresentou como objetivo a construção e operação de um prot´tipo de equipamento para produzir e armazenar energia a partir de materiais recicláveis, pela adaptação das bicicletas ergométricas presentes em academias, para fins não comerciais. Foi utilizado um alternador automotivo ligado por uma corrente à roda da bicicleta ergométrica, cuja energia gerada foi armazenada em uma bateria do tipo ácido-chumbo. A montagem do equipamento foi realizada, onde foi observada a produção de energia em velocidades acima de 15 km/h, medida na própria bicicleta. Essa velocidade esteve relacionada com o número de giros no eixo do alternador. Nessas condições, o carregamento completo de um smartphone padrão foi realizado em 6 h. Não foi necessária geração constante de energia para alimentar o sistema, apenas em intervalos de 40 min durante todo o processo. O carregamento completo do mesmo aparelho smartphone em na rede elétrica residencial de 220 V, durou 4 h.

Integrated Durability of Automobile Alternator Test System Design Based on LabVIEW

New standards in the automotive industry highlighted the situation of the actual operation of the alternator and a variety of harsh environment simulation limit test. Using new standards in the automotive industry as a guide, this article presents a virtual instrument based on the durability of automobile generator integrated test system. The design adopt virtual instrument technology in designing the system, Graphic language, LabVIEW is applied in writing measure-control program. The system uses a lot of features on LABVIEW, including Data acquisition, control of serials port, etc. Test implementation uses the host computer via RS232 and RS485 communication port and the data acquisition card, NI PCI- 6221, to control the frequency hybrid motor, temperature control box, electronic loads and other intelligent devices, and to simulate a variety of automotive alternator working conditions and real-time monitoring to monitor the status of generators. Using this system, two separate automobile alternators can be tested in terms of high-speed vehicle impact and high temperature durability test and electrical performance test and other tests at the same time. As a result, the generator speed measurement error is within 1%, the control error is within 2%, voltage and current measurement errors were within 0.5% and 0.4%, which meets the requirements.

The Research of Manufacturing Technique about Intertwined Stator Core in Automotive Alternator

Intertwined automobile generator stator core is made from twisted Strip steel with teeth. This winding process is different from the method of traditional laminated machining. Intertwined technique is a new method that for the manufacturing of stator cores in automotive alternators. The productive process include such key steps: Leveling of the bar-typed materials, stamping, enwinding, soldering and plastic. This methods has raised the production efficiency and used ratio of the materials, and even make a cost reduction compared with the traditional ways of strap-typed stator core manufacturing. They are able to make a substitution to the imported products by most automotive alternator enterprises as well as complete the blanks of domestic market and have a large extent of social and economic benefits.

Thermal Analysis of Stirling Engine to Power Automotive Alternator Using Heat from Exhaust Gases

This paper investigates the development of small scale beta type Stirling engine to recover the exhaust heat from the main engine and to drive the alternator (decouple it from the main engine), thus providing the required electrical power for onboard devices. The ideal adiabatic model was used to predict the thermodynamic performance of the engine. CFD investigation was also carried out to optimise the heater and the cooler geometry of the Stirling engine. The results showed that it is possible to generate a power output of 1.5-2kWe at an ideal thermal efficiency of 40% and engine overall weight of 11-14kg.

Fatigue behaviour FEM modeling of deep groove ball bearing mounted in automotive alternator submitted to variable loading

Ball bearings subsurface materials are subjected to rolling contact fatigue with multiaxial stress state during loading cycle. The complex operating conditions of automotive bearings are different from classic operating conditions their fatigue crack initiation predicted by standards can be seen underestimated. This work presents a numerical approach of ball bearings to evaluate its fatigue behaviour in order to predict the life. A preliminary study has been done to evaluate the load distribution in the bearings. The results are integrated in a numerical dynamic model to study the bearing material rolling fatigue behaviour in constant and variable loading cases. By using fatigue criteria and damage laws, the analysis of stress state in bearing material leads to life prediction or the number of cycles before crack initiations. These results are compared to current standard methods used for ball bearing life prediction.

Development of Accelerated Failure-free Test Method for Automotive Alternator Magnet

Development of Accelerated Failure-free Test Method for Automotive Alternator Magnet

Small wind power generation using automotive alternator

The objective of this paper is to evaluate the feasibility of using claw pole automotive alternator as a generator for small wind turbine and to compare its energy yield and generated electricity cost with commercially available systems. The comparison is based on the energy yield per swept area and cost per energy produced in a low wind speed climate. Concepts such as the selection of suitable turbine parameters and gear ratio were used to achieve good matching of the turbine characteristics with measured alternator performance in order to improve the energy yield from the alternator in battery charging application. The energy yield from the alternator integrated to a 3.9 m diameter turbine is comparable with many commercially available turbines. The generated electricity cost of a commercially available turbine can be reduced by more than a factor of 2 by replacing its generator with our proposed alternator. The alternator-based turbine system is therefore a low cost solution aimed at making wind energy available to areas where the current cost of wind technology makes it prohibitive.

A Stochastic Modeling Approach of Quantized Systems with Application to Fault Detection and Isolation of an Automotive Electrical Power Generation Storage System


 
 
 This paper introduces a stochastic modeling approach for a quantized system for the purpose of fault detection and isolation in an automotive alternator system. Three common alternator faults including belt slip, diode failure, and incorrect reference voltage for the voltage controller are considered and analyzed. A continuous nonlinear model of the alternator system is quantized into discrete states in order to simplify diagnostic efforts. The paper describes a stochastic modeling approach that creates a time-varying probability transition matrix that can be computed in real- time without the need for Monte Carlo simulation. Fault detection and isolation occurs through comparison of the most probable state from the transition matrix and the quantized output state.
 
 

Finite Element Simulation and Experimental Validation of Manufacturing Process for Alternator Housing

For the development of the manufacturing process of alternator housing, finite element simulation is applied. In recent years, automobile parts are required to be light and have high strength. The control of casting defects is important in die casting process. However, it has usually been depended on the experience of the foundry engineer. The die casting process was used to manufacture automotive alternator housings. In this paper, the die characteristics of alternator housing with the HPDC(High Pressure Die Casting) process were investigated using computer simulations. Through the simulations using the commercial software, the filling pattern and product defects could be confirmed. The computer simulation results of filling behavior were reflected to the optimal design of the alternator housing. The analysis results obtained from the filling behavior of casting process agreed with experimental results.

Research of Intelligent Automotive Alternator Control System to Reduce the Fuel Consumption

The amount and the power of the electrical appliances on cars are increasing, and the fuel consumption produced by the electrical system is getting larger. To design an automotive electrical power system with higher efficiency is a very practical requirement. In this paper, we proposed an automotive intelligent alternator control system. In this system, we divided the battery states to different partitions by state of charge, and designed an intelligent alternator control system to work in different mode according to the battery partition and the vehicle state. With this system we can realize the braking energy regeneration for traditional cars and reduced the fuel consumption. We carried out the experiment with a car, and the results indicated that with this system, the fuel consumption can be reduced by about 2-3%.

HV-CMOS Design and Characterization of a Smart Rotor Coil Driver for Automotive Alternators

The work presents a single-chip integrated rotor coil driver (RCD) that can be used in automotive alternators. It integrates the power switch with the control circuitry and the diagnostics; with respect to the state of the art, new functionalities are integrated such as full reverse polarity protection and programmable output slope control against in-rush currents and current spike transients. The paper will discuss the driver IC design from the choice of the architecture to the real silicon implementation. The proposed innovative RCD has been implemented in a 0.35 μm HV-CMOS technology and has been embedded in a mechatronic brush-holder regulator system-on-chip for an automotive alternator. The simulation results and experimental measurements prove the effectiveness of the proposed RCD facing the harshest automotive conditions.

Effect of open stator slots on the performance of an interior permanent magnet automotive alternator

This work describes a study of the effect of using open stator slots in an interior permanent magnet automotive alternator to increase its effective air gap and thus reduce its iron losses under field-weakening conditions. Analytical, finite-element and experimental results are compared for the back-electromotive waveforms, inductance saturation/torque curves, iron loss and field-weakening performance characteristics for the alternator with both semi-closed and with open slots. It is shown for the highly saturated machine considered, that using open stator slots can reduce the field-weakening iron loss without significantly affecting the machine performance.