![1966 AMC Ambassador 990 4-sp convertible AACA Iowa k](https://upload.wikimedia.org/wikipedia/commons/f/f2/1966_AMC_Ambassador_990_4-sp_convertible_AACA_Iowa_k.jpg)
An alternator is a type of
electric generator
In electricity generation, a generator is a device that converts motive power (mechanical energy) or fuel-based power (chemical energy) into electric power for use in an external circuit. Sources of mechanical energy include steam turbines, gas ...
used in modern
automobile
A car or automobile is a motor vehicle with Wheel, wheels. Most definitions of ''cars'' say that they run primarily on roads, Car seat, seat one to eight people, have four wheels, and mainly transport private transport#Personal transport, pe ...
s to charge the
battery
Battery most often refers to:
* Electric battery, a device that provides electrical power
* Battery (crime), a crime involving unlawful physical contact
Battery may also refer to:
Energy source
*Automotive battery, a device to provide power t ...
and to power the electrical system when its
engine
An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy.
Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power gen ...
is running.
Until the 1960s, automobiles used DC
dynamo
file:DynamoElectricMachinesEndViewPartlySection USP284110.png, "Dynamo Electric Machine" (end view, partly section, )
A dynamo is an electrical generator that creates direct current using a commutator (electric), commutator. Dynamos were the f ...
generators with
commutator
In mathematics, the commutator gives an indication of the extent to which a certain binary operation fails to be commutative. There are different definitions used in group theory and ring theory.
Group theory
The commutator of two elements, a ...
s. As
silicon-diode rectifiers became widely available and affordable, the
alternator
An alternator is an electrical generator that converts mechanical energy to electrical energy in the form of alternating current. For reasons of cost and simplicity, most alternators use a rotating magnetic field with a stationary armature.Go ...
gradually replaced the dynamo. This was encouraged by the increasing electrical power required for cars in this period, with increasing loads from larger headlamps, electric wipers,
heated rear windows, and other accessories.
History
The modern type of vehicle alternators were first used in military applications during
World War II
World War II or the Second World War, often abbreviated as WWII or WW2, was a world war that lasted from 1939 to 1945. It involved the vast majority of the world's countries—including all of the great powers—forming two opposin ...
, to power radio equipment on specialist vehicles. After the war, other vehicles with high electrical demands — such as ambulances and radio taxis — could also be fitted with optional alternators.
Alternators were first introduced as standard equipment on a production car by the
Chrysler Corporation
Stellantis North America (officially FCA US and formerly Chrysler ()) is one of the " Big Three" automobile manufacturers in the United States, headquartered in Auburn Hills, Michigan. It is the American subsidiary of the multinational automoti ...
on the
Valiant in 1960, several years ahead of
Ford
Ford commonly refers to:
* Ford Motor Company, an automobile manufacturer founded by Henry Ford
* Ford (crossing), a shallow crossing on a river
Ford may also refer to:
Ford Motor Company
* Henry Ford, founder of the Ford Motor Company
* Ford F ...
and
General Motors
The General Motors Company (GM) is an American Multinational corporation, multinational Automotive industry, automotive manufacturing company headquartered in Detroit, Michigan, United States. It is the largest automaker in the United States and ...
.
Magnetos in early automobiles
Some early automobiles, like the
Ford Model T
The Ford Model T is an automobile that was produced by Ford Motor Company from October 1, 1908, to May 26, 1927. It is generally regarded as the first affordable automobile, which made car travel available to middle-class Americans. The relati ...
, used a different sort of charging system: an engine-driven
magneto
A magneto is an electrical generator that uses permanent magnets to produce periodic pulses of alternating current. Unlike a dynamo, a magneto does not contain a commutator to produce direct current. It is categorized as a form of alternator, ...
which generated low-voltage alternating current that was supplied to
trembler coil
A trembler coil, buzz coil or vibrator coil is a type of high-voltage ignition coil used in the ignition system of early automobiles, most notably the Benz Patent-Motorwagen and the Ford Model T. Its distinguishing feature is a vibrating magnetica ...
s, which provided the high voltage needed to generate ignition sparks. (This was different from a true
ignition magneto
An ignition magneto, or high-tension magneto, is a magneto that provides current for the ignition system of a spark-ignition engine, such as a petrol engine. It produces pulses of high voltage for the spark plugs. The older term ''tension'' ...
, which generates high voltage directly.) Since such a magneto system only depended on the engine's motion to generate current, it could even be used when starting a manually cranked engine, provided the crank was pulled sharply, so that the magneto would produce enough current for the coils to make good sparks.
The Model T incorporated its magneto into the engine flywheel. The first Model Ts used the magneto solely for the trembler coil ignition. Beginning with the 1915 model year, Ford added electric headlights, also powered by the magneto. The magneto circuit was strictly AC, with no battery included. (There was a switch on the ignition coils to use a battery instead, which could be helpful when starting in cold weather, but Ford neither provided a battery nor did it encourage the use of one before it introduced an electric starter in 1919. The owner would have to install the battery themselves and charge it externally.)
Starting in the 1919 model year, Ford upgraded the Model T to include an electric starter, which was standard for some models and optional for others. This starter installation also included a battery, charged by a conventional dynamo, and the lights were now powered by the battery. However, the flywheel magneto still powered the ignition, and since models without the starter had no battery, they continued to use magneto-powered lights.
Advantages over dynamos
Alternator
An alternator is an electrical generator that converts mechanical energy to electrical energy in the form of alternating current. For reasons of cost and simplicity, most alternators use a rotating magnetic field with a stationary armature.Go ...
s have several advantages over direct-current generators (
dynamo
file:DynamoElectricMachinesEndViewPartlySection USP284110.png, "Dynamo Electric Machine" (end view, partly section, )
A dynamo is an electrical generator that creates direct current using a commutator (electric), commutator. Dynamos were the f ...
s). Alternators are:
* Lighter, cheaper, and more rugged
* Can provide useful charge at idle speed
* Use
slip ring
A slip ring is an electromechanical device that allows the transmission of power and electrical signals from a stationary to a rotating structure. A slip ring can be used in any electromechanical system that requires rotation while transmitting p ...
s, having greatly extended
brush
A brush is a common tool with bristles, wire or other filaments. It generally consists of a handle or block to which filaments are affixed in either a parallel or perpendicular orientation, depending on the way the brush is to be gripped durin ...
life over a
commutator
In mathematics, the commutator gives an indication of the extent to which a certain binary operation fails to be commutative. There are different definitions used in group theory and ring theory.
Group theory
The commutator of two elements, a ...
(Or completely brushless designs)
* The brushes in an alternator carry only
DC excitation current, which is a small fraction of the current carried by the brushes of a DC generator, which carry the generator's entire output
A set of
rectifier
A rectifier is an electrical device that converts alternating current (AC), which periodically reverses direction, to direct current (DC), which flows in only one direction. The reverse operation (converting DC to AC) is performed by an Power ...
s (
diode bridge
A diode bridge is a bridge rectifier circuit of four diodes that is used in the process of converting alternating current (AC) from the input terminals to direct current (DC, i.e. fixed polarity) on the output terminals. Its function is to co ...
) is required to convert
AC to
DC. To provide direct current with low
ripple
Ripple may refer to:
Science and technology
* Capillary wave, commonly known as ripple, a wave traveling along the phase boundary of a fluid
** Ripple, more generally a disturbance, for example of spacetime in gravitational waves
* Ripple (electri ...
, a
polyphase winding is used and the pole-pieces of the rotor are shaped (claw-pole). Automotive alternators are usually
belt
Belt may refer to:
Apparel
* Belt (clothing), a leather or fabric band worn around the waist
* Championship belt, a type of trophy used primarily in combat sports
* Colored belts, such as a black belt or red belt, worn by martial arts practit ...
-driven at 2–3 times crankshaft speed, speeds that could cause a commutator to fly apart in a generator. The alternator runs at various RPM (which varies the frequency) since it is driven by the engine. This is not a problem because the alternating current is
rectified to
direct current
Direct current (DC) is one-directional flow of electric charge. An electrochemical cell is a prime example of DC power. Direct current may flow through a conductor such as a wire, but can also flow through semiconductors, insulators, or even ...
.
Alternator regulators are also simpler than those for generators. Generator regulators require a cutout relay to isolate the output coils (the armature) from the battery at low speed; that isolation is provided by the alternator rectifier diodes. Also, most generator regulators include a current limiter; alternators are inherently current-limited.
Operation
![Dynamo](https://upload.wikimedia.org/wikipedia/commons/1/19/Dynamo.jpg)
The claw pole design produces an AC waveform that is more efficiently rectified than a sine wave.
Despite their names, both 'DC generators' (or 'dynamos') and 'alternators' initially produce alternating current. In a so-called 'DC generator', this AC current is generated in the rotating armature, and then converted to DC by the commutator and brushes. In an 'alternator', the AC current is generated in the stationary stator, and then is converted to DC by the rectifiers (diodes).
Typical passenger vehicle and light truck alternators use Lundahl or 'claw-pole' field construction. This uses a shaped iron core on the rotor to produce a multi-pole field from a single coil winding. The poles of the rotor look like fingers of two hands interlocked with each other. The coil is mounted axially inside this and field current is supplied by slip rings and carbon brushes. These alternators have their field and stator windings cooled by axial airflow, produced by an external fan attached to the drive belt pulley.
![Jeep 2](https://upload.wikimedia.org/wikipedia/commons/0/0e/Jeep_2.5_liter_4-cylinder_engine_chromed_e.jpg)
Modern vehicles now use the compact alternator layout. This is electrically and magnetically similar, but has improved air cooling. Better cooling permits more power from a smaller machine. The casing has distinctive radial vent slots at each end and now encloses the fan. Two fans are used, one at each end, and the airflow is semi-radial, entering axially and leaving radially outwards.
The stator windings now consist of a dense central band where the iron core and copper windings are tightly packed, and end bands where the windings are more exposed for better heat transfer. The closer core spacing from the rotor improves magnetic efficiency. The smaller, enclosed fans produce less noise, particularly at higher machine speeds.
Alternators can also be water-cooled in cars.
Larger vehicles may have
field coil
A field coil is an electromagnet used to generate a magnetic field in an electro-magnetic machine, typically a rotating electrical machine such as a motor or generator. It consists of a coil of wire through which a current flows.
In a rotating ...
alternators similar to larger machines.
The windings of a 3 phase alternator may be connected using either the ''delta'' or ''star'' (''wye'') connection regime set-up.
Brushless versions of these type alternators are also common in larger machinery such as highway trucks and earthmoving machinery. With two oversized shaft bearings as the only wearing parts, these can provide extremely long and reliable service, even exceeding the engine overhaul intervals.
Field regulation
Automotive alternators require a
voltage regulator
A voltage regulator is a system designed to automatically maintain a constant voltage. A voltage regulator may use a simple feed-forward design or may include negative feedback. It may use an electromechanical mechanism, or electronic components ...
which operates by modulating the small field current to produce a constant voltage at the battery terminals. Early designs (c.1960s–1970s) used a discrete device mounted elsewhere in the vehicle. Intermediate designs (c.1970s–1990s) incorporated the voltage regulator into the alternator housing. Modern designs do away with the voltage regulator altogether; voltage regulation is now a function of the
engine control unit
An engine control unit (ECU), also commonly called an engine control module (ECM), is a type of electronic control unit that controls a series of actuators on an internal combustion engine to ensure optimal engine performance. It does this by re ...
(ECU). The field current is much smaller than the output current of the alternator; for example, a 70
A alternator may need only 2-3 A of field current. The field current is supplied to the rotor windings by slip rings. The low current and relatively smooth slip rings ensure greater reliability and longer life than that obtained by a DC generator with its commutator and higher current being passed through its brushes.
The field windings are supplied with power from the battery via the ignition switch and regulator. A
parallel circuit
Terminal (electronics), Two-terminal components and electrical networks can be connected in series or parallel. The resulting electrical network will have two terminals, and itself can participate in a series or parallel Topology (electrical cir ...
supplies the "charge" warning indicator and is earthed via the regulator (which is why the indicator is on when the ignition is on but the engine is not running). Once the engine is running and the alternator is generating power, a
diode
A diode is a two-terminal electronic component that conducts current primarily in one direction (asymmetric conductance); it has low (ideally zero) resistance in one direction, and high (ideally infinite) resistance in the other.
A diode ...
feeds the field current from the alternator main output equalizing the voltage across the warning indicator which goes off. The wire supplying the field current is often referred to as the "exciter" wire. The drawback of this arrangement is that if the warning lamp burns out or the "exciter" wire is disconnected, no current reaches the field windings and the alternator will not generate power. Some warning indicator circuits are equipped with a resistor in parallel with the lamp that permit excitation current to flow if the warning lamp burns out. The driver should check that the warning indicator is on when the engine is stopped; otherwise, there might not be any indication of a failure of the belt which may also drive the cooling
water pump
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical action, typically converted from electrical energy into hydraulic energy. Pumps can be classified into three major groups according to the method they u ...
. Some alternators will self-excite when the engine reaches a certain speed.
In recent years, alternator regulators are linked to the vehicle's computer system and various factors including air temperature obtained from the intake air temperature sensor, battery temperature sensor and engine load are evaluated in adjusting the voltage supplied by the alternator.
Output current
Older automobiles with minimal lighting may have had an alternator capable of producing only 30
amperes
The ampere (, ; symbol: A), often shortened to amp,SI supports only the use of symbols and deprecates the use of abbreviations for units. is the unit of electric current in the International System of Units (SI). One ampere is equal to elect ...
. Typical passenger car and light truck alternators are rated around 50–70 A, though higher ratings are becoming more common, especially as there is more load on the vehicle's electrical system with
air conditioning
Air conditioning, often abbreviated as A/C or AC, is the process of removing heat from an enclosed space to achieve a more comfortable interior environment (sometimes referred to as 'comfort cooling') and in some cases also strictly controlling ...
,
electric power steering
A power steering is a mechanical device equipped on a motor vehicle that helps drivers steer the vehicle by reducing steering effort needed to turn the steering wheel, making it easier for the vehicle to turn or maneuver at lower speeds.
Hydraul ...
and other electrical systems. Very large alternators used on buses, heavy equipment or emergency vehicles may produce 300 A. Semi-trucks usually have alternators which output 140 A. Very large alternators may be water-cooled or oil-cooled.
Efficiency
Efficiency of automotive alternators is limited by fan cooling loss, bearing loss, iron loss, copper loss, and the voltage drop in the diode bridges. Efficiency reduces dramatically at high speeds mainly due to fan resistance. At medium speeds efficiency of today's alternators is 70–80%. This betters very small high-performance permanent magnet alternators, such as those used for
bicycle lighting
Bicycle lighting is illumination attached to bicycles whose purpose above all is, along with reflectors, to improve the visibility of the bicycle and its rider to other road users under circumstances of poor ambient illumination. A secondary p ...
systems, which achieve an efficiency around 60%. Larger permanent magnet electric machines (that can operate as motors or alternators) can achieve today much higher efficiencies. Pellegrino et al.,
[G. Pellegrino, A. Vagati, P. Guglielmi, "Performance Comparison Between Surface-Mounted and Interior PM Motor Drives for Electric Vehicle Application" IEEE Transactions on industrial electronics, vol 59, No 2, February 2012 pag. 809] for instance, propose not particularly expensive designs that show ample regions in which efficiency is above 96%. Large AC generators used in power stations run at carefully controlled speeds and have no constraints on size or weight. They have very high efficiencies as high as 98%.
Hybrid vehicles
Hybrid electric vehicle
A hybrid electric vehicle (HEV) is a type of hybrid vehicle that combines a conventional internal combustion engine (ICE) system with an electric propulsion system ( hybrid vehicle drivetrain). The presence of the electric powertrain is intende ...
s replace the separate alternator and starter motor with one or more combined motor/generator(s) that start the internal combustion engine, provide some or all of the mechanical power to the wheels, and charge a large storage battery. When more than one motor/generator is present, as in the
Hybrid Synergy Drive
Hybrid Synergy Drive (HSD), also known as Toyota Hybrid System II, is the brand name of Toyota Motor Corporation for the hybrid car drive train technology used in vehicles with the Toyota and Lexus marques. First introduced on the Prius, the tec ...
used in the
Toyota Prius
The is a car built by Toyota which has a Hybrid vehicle drivetrain, hybrid drivetrain, combining an internal combustion engine with an electric motor. Initially offered as a four-door Sedan (automobile), sedan, it has been produced only as ...
and others, one may operate as a generator and feed the other as a motor, providing an electromechanical path for some of the engine power to flow to the wheels. These motor/generators have considerably more powerful electronic devices for their control than the automotive alternator described above.
Footnotes
References
{{Authority control
Automobile
A car or automobile is a motor vehicle with Wheel, wheels. Most definitions of ''cars'' say that they run primarily on roads, Car seat, seat one to eight people, have four wheels, and mainly transport private transport#Personal transport, pe ...
Electrical generators
Automotive charging circuits