UIDE

International University of Ecuador

INTERNATIONAL UNIVERSITY OF ECUADOR

FACULTY OF AUTOMOTIVE ENGINEERING

ISSUE:
“DESIGN AND CONSTRUCTION OF A
TRAINING BENCH FOR ALTERNATORS AND STARTER MOTORS
”

DEGREE WORK PRIOR TO OBTAINING THE

DEGREE IN AUTOMOTIVE MECHANICS ENGINEERING

AUTHOR:
Erasmus Israel Garcia Ochoa

GUAYAQUIL – SEPTEMBER 2016

INTERNATIONAL UNIVERSITY OF ECUADOR

FACULTY OF AUTOMOTIVE MECHANICAL ENGINEERING

 CERTIFICATE
Eng. Edwin Puente Moromenacho

CERTIFIES:

That the work entitled “DESIGN AND CONSTRUCTION OF A TRAINING BENCH

FOR ALTERNATORS AND STARTER MOTORS. “, carried out by the student:
ERASMO ISRAEL GARCIA OCHOA, has been guided and periodically reviewed
and complies with the statutory standards established by the International University
of Ecuador, in the Student Regulations.
Because it constitutes a work of excellent scientific content that will contribute to the
application of knowledge and professional development. The aforementioned work
consists of a bound book and a compact disc containing the files in portable Acrobat
format. Authorizes Mr. Erasmo Israel García Ochoa to deliver it to the Faculty
library, in his capacity as custodian of bibliographic resources and materials.

Guayaquil, September 2016

INTERNATIONAL UNIVERSITY OF ECUADOR

 FACULTY OF AUTOMOTIVE MECHANICS ENGINEERING

DECLARATION OF LIABILITY

I, ERASMO ISRAEL GARCIA OCHOA

I DECLARE THAT:

The chair research called: “DESIGN AND CONSTRUCTION OF A

TRAINING BENCH FOR ALTERNATORS AND STARTER MOTORS” has been
developed based on exhaustive research, respecting the intellectual rights of third
parties, whose sources are incorporated in the bibliography.
Consequently, this work is my own, supported by the constant guidance of
my teacher.

By virtue of this declaration, I take responsibility for the content, veracity and
scientific scope for the Faculty of Automotive Mechanical Engineering.

Guayaquil, September 2016.

Erasmus Israel Garcia Ochoa

Cl 0917118697

INTERNATIONAL UNIVERSITY OF ECUADOR

 FACULTY OF AUTOMOTIVE MECHANICS ENGINEERING

AUTHORIZATION

I, ERASMO ISRAEL GARCIA OCHOA

I authorize the International University of Ecuador to publish in the

Institution's virtual library the chair research: "DESIGN AND CONSTRUCTION OF
A TRAINING BENCH FOR ALTERNATORS AND STARTER MOTORS", the
content, ideas and criteria of which are my exclusive responsibility and
authorship.

Guayaquil, September 2016

Erasmus Israel Garcia Ochoa

Cl 0917118697
 GENERAL INDEX

UIDE............................................................................................................................1
CERTIFICATE.....................................................................................................2
CERTIFIES:..........................................................................................................2
I DECLARE THAT:............................................................................................iii
I, ERASMO ISRAEL GARCIA OCHOA...........................................................iv
DEDICATION....................................................................................................13
GRATITUDE......................................................................................................13
GENERAL SUMMARY....................................................................................14
CHAPTER I..............................................................................................................1
CONTEXTUAL FRAMEWORK OF THE RESEARCH.......................................1
1.1 Problem definition.....................................................................................1
1.2 Location of the problem.............................................................................1
1.3 Problem formulation..................................................................................2
1.4 Systematization of the problem.................................................................2
1.5.1 General objective...................................................................................3
1.5.2 Specific objectives.................................................................................3
1.6 Scope..........................................................................................................3
1.7 Justification and importance of the research..............................................3
1.8 Hypothesis.................................................................................................4
CHAPTER II............................................................................................................4
THEORETICAL FRAMEWORK............................................................................4
2. Alternator...................................................................................................4
2.1 Generating electrical energy in the vehicle................................................5
Alternator principle...................................................................................................................7
2.1.1 Generation of rectified current by alternators........................................8
three-phase............................................................................................................8
2.1.2 Magnitudes that influence the operation of the alternator......................9
2.1.3 Alternator Requirements........................................................................9
2.2 Electrodynamic principle.........................................................................10
2.3 Principle of three-phase alternator...........................................................11
2.3.1 Rectification of the generated current..................................................13
2.3.2 Importance of battery polarities...........................................................14
2.3.3 Three-phase alternator current circuits.................................................15
 2.3.4 Pre-excitation circuit............................................................................15
2.3.5 Excitation circuit (self-excitation)........................................................16
2.3.6 Alternator current circuit...........................................................................17
Alternator circuit...................................................................................................................17
2.3.7 Regulation of the generated voltage.....................................................18
2.3.8 Alternator structure..............................................................................19
2.3.9 Stator....................................................................................................20
2.3.10 Rotor.................................................................................................20
2.3.11 Brush holder.....................................................................................21
2.4 Starter motor.................................................................................................22
2.4.1 Operating principle...............................................................................23
2.4.2 Left hand rule of generated intensity...................................................24
2.4.3 Starter motor parts................................................................................25
2.4.4 Operation of the starter motor..............................................................27
CHAPTER III.........................................................................................................27
TRAINING BENCH DESIGN...............................................................................27
3.1 Bending stress calculations...........................................................................28
Bending stress formula.......................................................................................29
Resolution...........................................................................................................29
Shear and bending stress.....................................................................................29
3.2. Electric motor installation calculation.........................................................30
1.3. Selection of materials...........................................................................32
1.4. Training bench structure design...........................................................33
CHAPTER IV.........................................................................................................35
CONSTRUCTION OF THE TRAINING BENCH...............................................35
4.2 Installing training bench components......................................................36
4.2.1 Starter motor installation......................................................................36
4.2.2 Alternator installation...........................................................................38
4.3.3 Electric motor control circuit installation..................................................40
4.3.4 Halogen electrical installation...................................................................45
4.3.5 12v control installation..............................................................................49
CHAPTER V..........................................................................................................52
FUNCTIONAL TESTS..........................................................................................52
5.1 Alternator Test.........................................................................................52
5.2 Testing the starter motor..........................................................................54
CHAPTER VI.........................................................................................................55
PREPARATION OF THE MAINTENANCE MANUAL AND...........................55
TRAINING BENCH OPERATION.......................................................................55
Introduction.........................................................................................................55
Goals...................................................................................................................55
ATTENTION!....................................................................................................55
ATTENTION!....................................................................................................55
CHAPTER VII.......................................................................................................63
CONCLUSIONS AND RECOMMENDATIONS.................................................63
7.1 Conclusions..............................................................................................63
7.2 Recommendations....................................................................................64
Appendix 2 – Alternator technical sheet................................................................66
Appendix 3 – Starter motor technical sheet...........................................................83
LITERATURE.......................................................................................................67
 INDEX OF FIGURES

Figura 1. Geographic location of the International University of Ecuador

UIDE..........................................................................................................................1
CERTIFICATE...................................................................................................2
CERTIFIES:........................................................................................................2
I DECLARE THAT:..........................................................................................iii
I, ERASMO ISRAEL GARCIA OCHOA.........................................................iv
DEDICATION..................................................................................................13
GRATITUDE....................................................................................................13
GENERAL SUMMARY..................................................................................14
CHAPTER I............................................................................................................1
CONTEXTUAL FRAMEWORK OF THE RESEARCH.....................................1
1.1 Problem definition...................................................................................1
1.2 Location of the problem...........................................................................1
1.3 Problem formulation................................................................................2
1.4 Systematization of the problem...............................................................2
1.5.1 General objective.................................................................................3
1.5.2 Specific objectives...............................................................................3
1.6 Scope........................................................................................................3
1.7 Justification and importance of the research............................................3
1.8 Hypothesis...............................................................................................4
CHAPTER II..........................................................................................................4
THEORETICAL FRAMEWORK..........................................................................4
2. Alternator.................................................................................................4
2.1 Generating electrical energy in the vehicle..............................................5
Alternator principle.................................................................................................................7
2.1.1 Generation of rectified current by alternators......................................8
three-phase..........................................................................................................8
2.1.2 Magnitudes that influence the operation of the alternator....................9
2.1.3 Alternator Requirements......................................................................9
2.2 Electrodynamic principle.......................................................................10
2.3 Principle of three-phase alternator.........................................................11
2.3.1 Rectification of the generated current................................................13
2.3.2 Importance of battery polarities.........................................................14
 2.3.3 Three-phase alternator current circuits...............................................15
2.3.4 Pre-excitation circuit..........................................................................15
2.3.5 Excitation circuit (self-excitation)......................................................16
2.3.6 Alternator current circuit.........................................................................17
Alternator circuit.................................................................................................................17
2.3.7 Regulation of the generated voltage...................................................18
2.3.8 Alternator structure............................................................................19
2.3.9 Stator..................................................................................................20
2.3.10 Rotor...............................................................................................20
2.3.11 Brush holder...................................................................................21
2.4 Starter motor...............................................................................................22
2.4.1 Operating principle.............................................................................23
2.4.2 Left hand rule of generated intensity.................................................24
2.4.3 Starter motor parts..............................................................................25
2.4.4 Operation of the starter motor............................................................27
CHAPTER III.......................................................................................................27
TRAINING BENCH DESIGN.............................................................................27
3.1 Bending stress calculations.........................................................................28
Bending stress formula.....................................................................................29
Resolution.........................................................................................................29
Shear and bending stress...................................................................................29
3.2. Electric motor installation calculation.......................................................30
1.3. Selection of materials.........................................................................32
1.4. Training bench structure design.........................................................33
CHAPTER IV.......................................................................................................35
CONSTRUCTION OF THE TRAINING BENCH.............................................35
4.2 Installing training bench components....................................................36
4.2.1 Starter motor installation....................................................................36
4.2.2 Alternator installation.........................................................................38
4.3.3 Electric motor control circuit installation................................................40
4.3.4 Halogen electrical installation.................................................................45
4.3.5 12v control installation............................................................................49
CHAPTER V........................................................................................................52
FUNCTIONAL TESTS........................................................................................52
5.1 Alternator Test.......................................................................................52
5.2 Testing the starter motor........................................................................54
 CHAPTER VI.......................................................................................................55
PREPARATION OF THE MAINTENANCE MANUAL AND.........................55
TRAINING BENCH OPERATION.....................................................................55
Introduction.......................................................................................................55
Goals.................................................................................................................55
ATTENTION!..................................................................................................55
ATTENTION!..................................................................................................55
CHAPTER VII.....................................................................................................63
CONCLUSIONS AND RECOMMENDATIONS...............................................63
7.1 Conclusions............................................................................................63
7.2 Recommendations..................................................................................64
Appendix 2 – Alternator technical sheet..............................................................66
Appendix 3 – Starter motor technical sheet.........................................................83
LITERATURE.....................................................................................................67
Figura 54.
INDEX OF TABLES

UIDE..........................................................................................................................1
CERTIFICATE...................................................................................................2
CERTIFIES:........................................................................................................2
I DECLARE THAT:..........................................................................................iii
I, ERASMO ISRAEL GARCIA OCHOA.........................................................iv
DEDICATION..................................................................................................13
GRATITUDE....................................................................................................13
GENERAL SUMMARY..................................................................................14
CHAPTER I............................................................................................................1
CONTEXTUAL FRAMEWORK OF THE RESEARCH.....................................1
1.1 Problem definition...................................................................................1
1.2 Location of the problem...........................................................................1
1.3 Problem formulation................................................................................2
1.4 Systematization of the problem...............................................................2
1.5.1 General objective.................................................................................3
1.5.2 Specific objectives...............................................................................3
1.6 Scope........................................................................................................3
1.7 Justification and importance of the research............................................3
1.8 Hypothesis...............................................................................................4
CHAPTER II..........................................................................................................4
THEORETICAL FRAMEWORK..........................................................................4
2. Alternator.................................................................................................4
2.1 Generating electrical energy in the vehicle..............................................5
Alternator principle.................................................................................................................7
2.1.1 Generation of rectified current by alternators......................................8
three-phase..........................................................................................................8
2.1.2 Magnitudes that influence the operation of the alternator....................9
2.1.3 Alternator Requirements......................................................................9
2.2 Electrodynamic principle.......................................................................10
2.3 Principle of three-phase alternator.........................................................11
2.3.1 Rectification of the generated current................................................13
2.3.2 Importance of battery polarities.........................................................14
2.3.3 Three-phase alternator current circuits...............................................15
2.3.4 Pre-excitation circuit..........................................................................15
2.3.5 Excitation circuit (self-excitation)......................................................16
2.3.6 Alternator current circuit.........................................................................17
Alternator circuit.................................................................................................................17
2.3.7 Regulation of the generated voltage...................................................18
2.3.8 Alternator structure............................................................................19
2.3.9 Stator..................................................................................................20
2.3.10 Rotor...............................................................................................20
2.3.11 Brush holder...................................................................................21
2.4 Starter motor...............................................................................................22
2.4.1 Operating principle.............................................................................23
2.4.2 Left hand rule of generated intensity.................................................24
2.4.3 Starter motor parts..............................................................................25
2.4.4 Operation of the starter motor............................................................27
CHAPTER III.......................................................................................................27
TRAINING BENCH DESIGN.............................................................................27
3.1 Bending stress calculations.........................................................................28
Bending stress formula.....................................................................................29
Resolution.........................................................................................................29
Shear and bending stress...................................................................................29
3.2. Electric motor installation calculation.......................................................30
1.3. Selection of materials.........................................................................32
 1.4. Training bench structure design.........................................................33
CHAPTER IV.......................................................................................................35
CONSTRUCTION OF THE TRAINING BENCH.............................................35
4.2 Installing training bench components....................................................36
4.2.1 Starter motor installation....................................................................36
4.2.2 Alternator installation.........................................................................38
4.3.3 Electric motor control circuit installation................................................40
4.3.4 Halogen electrical installation.................................................................45
4.3.5 12v control installation............................................................................49
CHAPTER V........................................................................................................52
FUNCTIONAL TESTS........................................................................................52
5.1 Alternator Test.......................................................................................52
5.2 Testing the starter motor........................................................................54
CHAPTER VI.......................................................................................................55
PREPARATION OF THE MAINTENANCE MANUAL AND.........................55
TRAINING BENCH OPERATION.....................................................................55
Introduction.......................................................................................................55
Goals.................................................................................................................55
ATTENTION!..................................................................................................55
ATTENTION!..................................................................................................55
CHAPTER VII.....................................................................................................63
CONCLUSIONS AND RECOMMENDATIONS...............................................63
7.1 Conclusions............................................................................................63
7.2 Recommendations..................................................................................64
Appendix 2 – Alternator technical sheet..............................................................66
Appendix 3 – Starter motor technical sheet.........................................................83
LITERATURE.....................................................................................................67
 DEDICATION

To my parents for giving me life and for being the motivation to finish my
university career because thanks to their advice and daily effort they are seeing
the fruits of their hard work. THANK YOU.

I dedicate this work to my Uncle Manuel and Lucha because thanks to them
I had the opportunity to get out of the medical problem I had and to learn the path
of the Lord Jehovah.

To my girlfriend because I had her unconditional support and she offered

her time and advice when it was needed.

To my professors at the International University of Ecuador who have

contributed all their knowledge and experiences to continue growing and becoming
a professional.

Erasmus Israel Garcia Ochoa

GRATITUDE

I would like to thank with all my heart my parents, who worked hard to
shape me as a human being and as a professional, and my friend, Eng. Daniel
Bayas Senisterra for guiding me and giving me technical advice with this project.
 A very special thanks to my tutor, Eng. Edwin Puente, for guiding me to the
good growth and success of this project.

Erasmus Israel Garcia Ochoa

GENERAL SUMMARY

At the Faculty of Automotive Engineering, Guayaquil extension belonging to

the International University of Ecuador, the subjects of Automobile Electricity I and
II are taught in its curriculum. Which require describing, verifying, observing the
operating principle of the charging system and the starting system, these practices
require the existence of the tangible physical elements of the parts of the
aforementioned systems.

The absence of a training bench for alternators and starter motors leads to
students having unclear theoretical and practical knowledge.

The subsequent training bench for alternators and starter motors would be
a support for the practices related to the charging and starting system, because
also at a national level the most common problems in vehicles are the defects in
the electrical charging and starting system, and because for a long time, the
degree of complexity has been very high when diagnosing and fixing faults,
referring to the aforementioned systems.
 The purpose of designing this training bank is to meet all these needs for
the students of the International University of Ecuador, Guayaquil extension, so
that in the future of their professional life they will not have any problems when
they encounter these systems.

ABSTRACT

The Faculty of Automotive Engineering, Guayaquil extension part of the

International University of Ecuador, in its curriculum subjects Electric Motor I and II
is taught. Which require describe, verify, observe the principle of operation of the
charging system and the system boot, these practices require the existence of
tangible physical elements of the parts of the aforementioned systems.

The absence of a workout bench for alternators and starter motors

encourages not have clear knowledge and skills for students.

The resulting training bench for alternators and starter motors will and be a
support for practices related to the charging system and boot, because also at
national level the most common problems in vehicles are damage to electrical
charging system and boot, and because in a long time , It has been very high
degree of complexity instantly diagnose and fix faults concerning the
aforementioned systems.

The proposed training design this bank is to supply all these needs for
students of the International University of Ecuador Guayaquil extension, so that in
the future of their professional life they do not have disadvantages when they are
with these systems.
 INTRODUCTION

The automotive industry has experienced exponential technological growth,

in line with the requirements of today's world.

Currently using sensors to control the charging and starting systems, which
are some of the most complex parts of the vehicle. As the power supply to the
batteries they carry inside; the engine starts when it is static and needs to be
started to have better driving in different scenarios.

These systems are currently present in most vehicles to improve fuel

consumption and reduce gas emissions into the atmosphere.

The charging system is responsible for constantly supplying DC1 direct

current energy to the battery so that it does not completely discharge.

The starter system is responsible for starting the internal combustion

engine from a standstill. This system only works when the MCI2 internal
combustion engine is at rest; but in the new systems, it is constantly used while the
vehicle is in motion.

This present work contemplates the design and construction of a training

bench for alternators and starter motors, and for the diagnosis of the systems.

The implementation of this project contributes to the technical training of

student staff within their environment.
 CHAPTER I

CONTEXTUAL FRAMEWORK OF THE RESEARCH

1.1 Problem definition

At the Faculty of Automotive Engineering, Guayaquil extension belonging to

the International University of Ecuador, the subjects of Automobile Electricity I and
II are taught in its curriculum.

Which require describing, verifying, observing the operating principle of the

charging system and the starting system, these practices require the existence of
the tangible physical elements of the parts of the aforementioned systems. Without
a training bench for alternators and starter motors, the theoretical and practical
knowledge for students is not clear.

The subsequent training bench for alternators and starter motors would be
a support for the practices related to the subject, because also at a national level
the most common problems in vehicles are defects in the electrical system, and
because for a long time; the degree of complexity has been very high when
diagnosing and fixing faults, concerning the systems.

The purpose of designing this training bench is to meet all these needs for
the students of the International University of Ecuador, Guayaquil extension, so
that in the future of their professional life they will not have any problems when
they encounter these electrical charging and starting systems.

1.2 Location of the problem

The time frame was determined from April to September 2016, during which
time the research was carried out and the relevant proposal was presented.

The geographical delimitation is in the Faculty of Automotive Engineering,

Guayaquil extension belonging to the International University of Ecuador.
In the workshops located at: Av. Tomas Martinez and Rocafuerte. Fig. 1

1
 Figure 1. Geographic location of the International University of Ecuador Guayaquil
Extension Source: https://www.google.com.ec/maps/
Edited by: Erasmo Garcia Ochoa

1.3 Problem formulation

Is it really necessary to design a training bench for alternators and starter

motors?

1.4 Systematization of the problem

Can we check the readings of the charging and starting system?

How will the charging and starting system performance measurements be

performed?

How can connections be established to be executed by students?

1.5 Research objectives

2
1.5.1 General objective

Design and build a training bench for alternators and starter motors.

1.5.2 Specific objectives

• Design an alternator and starter motor training bench that fits and satisfies
the automotive electricity area.
• Determine the components that must structure a training bench for
alternators and starter motors so that its configuration complies with the
required standards.

• Build an efficient bank so that adaptation is not a safety issue for teachers
and students who would use it for educational purposes.

• To allow students to obtain guidelines when diagnosing charging and

starting systems.

1.6 Scope

The subsequent training bank aims to be a support tool in the practices

related to the operation of the charging and starting system of vehicles, the
proposal to create a learning module to help students of the International
University of Ecuador, Guayaquil extension, to know and detect failures in a fast
and effective way.

1.7 Justification and importance of the research

In the work carried out, data sheets of alternators and starter motors given
by the manufacturer will be taken. These would support the operation of the
systems with the objective that the teaching staff have the appropriate tools for
teaching their classes and this would also improve the learning environment for
students, which would be very well received by all the staff of the International
University of Ecuador.

To carry out this research, scientific, investigative and field methodologies

will be adopted. Information from books and manuals will also be used to acquire
knowledge and experience in the use of charging and starting systems.

3
 With the design of this training bench, students will be able to practice the
charging and starting system and have solid knowledge about the operation of
these systems.

1.8 Hypothesis

Design and implement a training bench for the charging and starting system
in the vehicle.

CHAPTER II

THEORETICAL FRAMEWORK

2. Alternator

The requirements placed on the electrical supply in vehicles have grown

considerably since the 1970s and 1990s. The power required by the alternator
increased approximately two and a half times, and by the year 2000 an additional
doubling of the average power demand is expected. Since the three-phase
alternator was introduced, its size has been reduced compared to its predecessor,
the dynamo, despite the increase in power, while its range of high rotation speeds
has been simultaneously expanded.

The large variations in rotational speeds and the large load fluctuations of a
combustion engine also require a regulation system that can withstand the
alternator voltage. Electronic regulators are wear-free, lightweight and small in
size, and are able to constantly maintain alternator voltage at any engine speed.

In practice, the alternator is a relatively small element if we take into account

the power it supplies to the electrical and electronic installations of the vehicle and
the number of DC6 electric motors, lights and appliances it can operate at the same
time. Its location is always close to the crankshaft pulley since this is the driver of
the alternator and must always be moved to transform the mechanical energy it
receives into electrical energy. Fig. 2

6 Direct current.

4
 Figure 2. Location of the alternator in the car Source: Erasmo Israel García Ochoa

2.1 Generating electrical energy in the vehicle

Vehicles with internal combustion engines require an efficient energy source

that is available at all times to supply energy to the starter motor, injection and
ignition system, electronic control units, safety and comfort electronics, lighting,
etc. The alternators used in the automotive industry have three-phase electrical
characteristics, which means that they have three groups of windings, each of
which collaborates in the work of generating current.

Meanwhile, in vehicles the battery has a very important role, which is to

accumulate energy when the MCI7 is at rest, but when the engine starts to operate,
the alternator becomes a true "power station" of the car. Its main mission is to
supply power to all electrical devices in the vehicle. Fig. 3

7 Internal combustion engine.

5
 Alternator principle.
The alternator supplies rectified three-phase current to supply electrical appliances and to
charge the battery.

Three-phase current

Electrical
appliances

Figura 3. Principle of alternator

Source: Manual of automobile technology, 2005,
BoschEdited by: Erasmo Garcia Ochoa

In Figure 4 we have a fairly simple diagram of the electrical structure of an

alternator.

1. Stator
2. Rotor
3. Slip rings
4. Rectifier diodes

Figura 4. Electrical diagram of an alternator

Source: Book, Car Electricity – 1, 2011, Vicente
CastroEdited by: Erasmo Garcia Ochoa

6
2.1.1 Generation of rectified current by alternators
three-phase

In the rectification of the generated current, the availability of power diodes

dates back to 1963 because it was one of the conditions previously for the
introduction of three-phase alternators by some manufacturers. Due to its high
electromagnetic efficiency, conditioned by its execution and by the speed range of
the direct current generator, the three-phase synchronous alternator is efficient
enough to deliver power even at low rpm at idle. When the battery is available and
has to store electrical energy, it must be able to provide direct current. In fact, if it
were not for the battery and the starter motor, a car installation could also run on
alternating current.

The increased power demand is due to the large number of electrical and
electronic devices installed in the vehicle. Fig. 5

The Figura 5. Evolution of alternator power Source: Bosch Alternator,

2000, Bosch Edited by: Erasmo Garcia Ochoa sized for charging
Three-phase voltages of 14 V and 28 V (for industrial vehicles). In the stator
alternators are there is a three-phase current winding and in the rotor there is
the excitation winding which is a winding of circular or flat
conductors around an iron core. The generated three-phase alternating current is
subjected to rectification.

7
2.1.2 Magnitudes that influence the operation of the alternator

The magnitudes that have the greatest influence on alternator performance

are:

• Rotational speed: The performance of an alternator (generatable

energy per kg of mass) increases with the rotational speed;
therefore, the reduction ratio between the engine crankshaft and the
alternator must be as high as possible. In the personal vehicle
sector, typical values are between 1:2 and 1:3; in the heavy vehicle
sector, they reach 1:5.

• Temperature: Losses in the alternator raise the temperature of the

components. Supplying fresh air to the alternator is a suitable
measure to reduce the temperature of components and thus
increase the service life of the alternator and its efficiency.

• Vibrations: Depending on the installation conditions and vibration

characteristics of the motor, vibration accelerations of up to 500…
800 m/s2 occur.

• Other influences: The alternator is also exposed to the influence of

water splashes, dirt, oil and fuel mist.

2.1.3 Alternator Requirements

The essential characteristics of the three-phase alternator are as follows:

• Power delivery even at idle.

• Rectification of three-phase current with power diodes in the three-
phase bridge circuit.
• Diodes separate the alternator from the battery and the vehicle's
electrical system when the alternator voltage is lower than the
battery voltage.

• Greater electrical efficiency (i.e., with equal power, three-phase

8
 alternators are lighter than direct current generators).

• Long life (conventional car alternators have a lifespan comparable to

that of the vehicle's engine; up to 150,000 km, so they do not require
maintenance during that time).

• The most robust alternators for industrial vehicles are manufactured

in versions without slip rings, either with re-lubrication possibilities or
equipped with bearings with grease reserve chambers.

• They are insensitive to external influences such as high

temperatures, humidity, dirt and vibrations.
• They can operate in both directions of rotation without requiring
special measures, provided that the shape of the fan is appropriate
to the corresponding direction of rotation.

2.2 Electrodynamic principle

The basis of all voltage generation is electromagnetic “induction” which

takes place in the following process:

"If an electrical cable or conductor moves cutting the lines of force of a

magnetic field, an electrical voltage (induced) is generated in said conductor."
It is irrelevant whether the magnetic field is fixed and the conductor moves,
or whether, on the contrary, the conductor is fixed and the magnetic field moves.

By connecting a voltmeter, with slip rings and carbon brushes, to the ends
of a conductive coil that rotates between the north and south poles of a permanent
magnet, a variable voltage can be read due to the constantly changing situation
with respect to the poles. If the rotation of the conducting coil is uniform, the
voltage curve is sinusoidal, with the maximum values appearing after each half
turn. If the current circuit is closed, an “alternating current” flows. Fig. 6

9
 Figure 6. Voltage curve of a winding rotating in a magnetic field Source: Charging and
starting system, 2012, Margarita Calsina Edited by: Erasmo Garcia Ochoa
2.3 Principle of three-phase alternator

Single-phase alternating current, three-phase alternating current is generated

in alternators by means of a rotary movement. The advantages of three-phase
alternating current are that it allows better use of the alternator than single-phase
current.

According to the principle, there are three equal and independent windings in
the armature, displaced 120° from each other. It is common to use abbreviations to
identify each of the windings with u, v, w being the beginnings of the winding and
x, y, z being the ends. According to the principle of induction, when the rotor
rotates, alternating sinusoidal voltages of equal magnitude and frequency are
generated in the windings. Due to the 120° displacement between the windings,
the alternating voltages generated in them are out of phase with each other by
120° and are therefore also out of phase in the rotation time. In this way a cycle
takes place that is constantly repeated. The resulting three-phase alternating
current produces a rotating magnetic field in a suitable motor. Fig. 7

UV w

1
0
Figure 7. Three-winding voltage curve at 120° angle Source: Manual de la técnica de la
automotriz, 2005, Bosch Edited by: Erasmo Garcia Ochoa

1
1
2.3.1 Rectification of the generated current

The alternating voltage generated by the three-phase alternator is not

suitable for the vehicle's battery or for supplying power to the control units inside
the vehicle, since they are electronically controlled.

To rectify the alternating current into direct current, we will use diodes. The
alternator uses the same procedure, and since the diodes have the same
appropriately reduced size, even though they are power diodes, they can be
incorporated into a diode holder plate that is part of the alternator squares. By
means of this diode bridge, the rectification of the generated current is established.
Fig. 8

Edited by: Erasmo Garcia Ochoa

The current reaching the diode through the (anode) is alternating and the
diode only allows the positive half-waves to pass, which are those shown at the
output of the diode (cathode).

The alternator power diodes on the positive and negative sides mostly
coincide in their function. They only differ in their structure intended for rectification
in the alternator and are called positive diodes and negative diodes.5

Three-phase alternators usually have a power rectifier diode bridge made

up of six units, two for each of its phases.

The alternator current generating coils, arranged in a star pattern; the

rectifier diode bridge and its connection to the accumulator battery. It is also

5
Bosch Alternators, Rectifier Diodes

1
2
necessary to take into account the presence of the capacitor to absorb the
overcurrents that may occur during the operation of the rectifier. Fig. 9

Figure 9. Three-phase alternator with 6-diode rectifier Source: Book, Automobile

Electricity – 1, 2011, Vicente Castro Edited by: Erasmo Garcia Ochoa

2.3.2 Importance of battery polarities

A reversal of the polarity of the battery or alternator cables connected

backwards in the installation would leave the entire circuit in short-circuit
conditions with the consequent possibility of rapid deterioration of the diodes. Fig.
10

1
3
 Figure 10. C of polarity
Source: Book, Car Electricity – 1, 2011, Vicente Castro Edited by:
Erasmo Garcia Ochoa

2.3.3 Three-phase alternator current circuits

Three-phase alternators have, in their standard version, three current

circuits:

• Pre-excitation circuit (external excitation by battery current).

• Excitation circuit (self-excitation).

• Alternator circuit or main circuit.

2.3.4 Pre-excitation circuit

The pre-excitation circuit corresponds to the moment the ignition switch is

turned on, energy flows from the battery, through the alternator charge indicator
light, and through the rotor excitation winding, and through the regulator to ground.
Fig. 11

This battery current causes the pre-excitation of the alternator in the rotor. 6

6
Bosch Alternators, Pre-excitation Circuit

1
4
□ Alternator assembly
(induced and inductors), rectifier bridge and regulator
□ Battery
□ Ignition key

D Instrument panel warning light

□ Regulator

E Direct positive battery line

E Positive line with the
ignition key on

The mass line

Figure 11. Pre-Excitation
CircuitSource: Charging and starting
system, 2012, Margarita Calsina
Edited by: Erasmo Garcia Ochoa

Why is pre-excitation necessary?

The voltage induced by remanence in the iron core of the excitation winding
is very low in most three-phase alternators during starting and at low revolutions.7

2.3.5 Excitation circuit (self-excitation)

The excitation circuit (self-excitation) starts when the vehicle's MCI is

rotating and, therefore, the alternator is already generating electricity. In this circuit
the excitation intensity is taken by the inductor coils from the output of the induced
coils.

The differences between the pre-excitation and self-excitation circuits are that one
runs at rest and the other in motion. Fig. 12
Excitation circuit.
1 Alternator,
the Excitation Diodes,
1 b Positive plate diodes.
1c Negative plate diodes,
1d Excitation winding.
2 Regulator,
3 Alternator control lamp.
4 Ignition switch.
5 Battery.

6
Bosch Alternators, Pre-excitation Circuit

1
5
 Figure 12. Excitation Circuit Source: Bosch Alternator, 2000, Bosch Edited by: Erasmo
Garcia Ochoa

2.3.6 Alternator current circuit

The alternating current is induced in the three phases of the alternator and
has to be rectified by the bridge circuit equipped with power diodes, to then be
transmitted to the battery and all the consumer components.

The alternator current is divided into battery charging current and the
supply current to the consumer components. This effect is based on the fact that,
for each of the possible rotor positions, all the diodes participate in the
rectification. In order for a current to flow from the alternator to the battery, the
voltage of the alternator must be slightly higher than that of the battery. Fig. 13
Alternator circuit.
1 Alternator, 1a Excitation diodes.
1b Positive plate diodes.
1c Negative plate diodes, 1d Excitation winding.
2 Regulator. 3 Alternator control lamp.
4 Power switch. 5 Battery

6
Bosch Alternators, Pre-excitation Circuit

1
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 Figure 13. Alternator circuit
Source: Bosch Alternator, 2000, Bosch Edited by: Erasmo Garcia Ochoa

2.3.7 Regulation of the generated voltage

The alternator voltage regulator has the mission of regulating the voltage
and maintaining the alternator voltage constant, and the regulation of the current in
an electric dynamo type generating machine and it has been seen that the
difference in the rotation regime to which these machines are subjected by virtue
of the rotation of the MCI determines a greater or lesser production of electrical
values of voltage and intensity.

But when charging the battery, its electrochemical properties must be

considered. In normal values, the level at which the regulator limits the alternator
voltage is 22º when cold, and slightly higher 80º when hot, to improve battery
charging.

To control the voltage values we can only act on the magnetic flux which,
since it is an electromagnet, we can control in the sense of providing it with a
greater or lesser amount of current, thereby increasing or decreasing the density
of the magnetic flux and establishing a relationship:

• Higher number of r/min → lower flow

• Lower number of r/min → increased flow8

8 Voltage regulator, Automotive electricity I

6
Bosch Alternators, Pre-excitation Circuit

1
7
 The electrical systems of cars with 12 V battery voltage are regulated within
the tolerance range of 14 V, and those of cars with 24 V. As long as the voltage
generated by the alternator remains lower than the regulation voltage, the voltage
regulator does not disconnect.9

2.3.8 Alternator structure

The different versions of alternators that exist on the market differ in certain
details depending on the field of application. In most motor vehicles, alternators
with intercalated poles with a monobloc structure are installed, but this has led to
the use of increasingly more compact alternators.

The main differences between the structure of the compact and monobloc
alternators are the two lower fans, the smaller slip rings and the position of the
rectifier diode plate, which is now located outside the slip ring bearing plate.

9 Principle of voltage regulation, Bosch alternators

6
Bosch Alternators, Pre-excitation Circuit

1
8
2.3.9 Stator

The stator is made of iron plates or a firm sheet metal core. Between which
slots have been left so that the coils can be placed. In the alternator, the number of
coils can be variable. In the case of figure 14 of the stator there are 18 coils that
are housed in 36 slots. The connection in the stator coil is of the star type and at
the ends of the cables, indicated in 1, to the terminals of each of the phases, which
are 3 because it is a three-phase winding, while in 3 you can see the connection
pin of the center of the coils that forms the star of the winding. On terminal 2, there
is a flat pin connection for the charging system warning light.

Figure 14. Stator

Source: Book, Car Electricity – 1, 2011, Vicente
CastroEdited by: Erasmo Garcia Ochoa

2.3.10 Rotor

The rotor has an axis and intercalated magnetic poles, which is the
excitation winding, both act as fans, and has bearings and collector rings. The
rotor has the particularity that it can regulate the magnetism of the poles and can
also regulate the current produced.

1
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The rotors consist of two partially interlocking polar rotating elements with paired
salient poles, inside which the exciter winding is placed, which is common to all
poles. Fig. 15

Figure 15. Rotor

Source: Book, Car Electricity – 1, 2011, Vicente Castro Edited by: Erasmo Garcia Ochoa

2.3.11 Brush holder

The excitation current flows through the brushes and the collector rings to
the rotating excitation winding. The brush holder is a single piece since both
brushes are very close together and do not need to occupy a strategic position as
is the case with the brushes of dynamos.

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0
 The brushes are divided into positive brushes and negative brushes and
these are connected to the slip rings which are positive and negative. Fig. 16

Figure 16. Toilet brush holder

Source: Book, Car Electricity – 1, 2011, Vicente
CastroEdited by: Erasmo Garcia Ochoa

2.4 Starter motor

The starter motor system rotates the ICM10 crankshaft at a speed fast enough
to start the ICM. Through a circuit of heavy and thick cables, since 950 Amps pass
through here, the connectors and switches, the current from the battery travels to
the ignition motor, which turns the crankshaft and, when everything is working
properly, starts the engine. Fig. 17

Figure 17. Components of the starting system

Source: http://www.autobild.es/practicos/sistema-start-stop-prueba-ahorro-combustible-
166409 Edited by: Erasmo Garcia Ochoa
2.4.1 Operating principle

A conductor traversed by an electric current within a magnetic field is

10 Internal combustion engine.

2
1
subjected to a force that tends to displace it11. Fig. 18

Figure 18. Ejection force

Source: Book, Car Electricity – 1, 2011, Vicente Castro Edited by: Erasmo Garcia Ochoa

Electricity is produced when a conducting wire moves through the lines of

force of a magnetic field.12

If the conductor were to move perpendicularly to the lines of force produced

in the magnetic field, whether generated by permanent magnets or field coils, but
when they were cut, electricity would be created in it.

All magnets have a south pole and a north pole, so if we introduce a

magnet into the magnetic field of another and confront them by their same pole,
they will repel each other and both will move, generating a repulsive force. Fig. 19
and Fig. 20

11 Current passing through a magnetic field, Car electricity I

12 Electric power generation, MacMillan charging and starting system

2
2
 Figure 19. Transformation of current 1
Source: Charging and starting system, 2012, Margarita Calsina Edited by: Erasmo Garcia
Ochoa

If the conductor were to move parallel to the lines of force of the magnetic
field and, by not cutting them, no electricity would be created in it. Fig. 20

Figure 20. Transformation of current 2

Source: Charging and starting system, 2012, Margarita Calsina Edited by: Erasmo Garcia
Ochoa

2.4.2 Left hand rule of generated intensity

The direction of movement of the conductor depends on the direction of the

magnetic field lines and the current in the conductor. This sense can be completed
by using the three-finger rule of the left hand. Fig. 21

2
3
 Figure 21. Three Finger Rule
Source: https://es.wikipedia.org/wiki/Regla_de_la_mano_izquierda
Edited by: Erasmo Garcia Ochoa

In Fig. 22 is a graphic representation of the rotation of electric motors, when

the movement of the conductors through a magnetic field occurs.

Figure 22. Intensity generated by rotating the coil inside the magnetic fieldSource
: Charging and starting system, 2012, Margarita
CalsinaEdited by: Erasmo Garcia Ochoa
2.4.3 Starter motor parts

The parts that make up the starter motor are:

• Electric motor (E): This is what transforms the electrical energy of the
battery into a rotation.
• Pinion assembly (P): It is responsible for transmitting the rotation
produced by the electric motor to the crankshaft through the flywheel.

2
4
 • Contactor or automatic (C): Connects and disconnects the pinion with
the flywheel, but also has the functionality of acting as a relay, reducing
the voltage drop between the battery and the electric motor. Fig. 23

Figure 23. Starter motor parts

Source: Charging and starting system, 2012, Margarita Calsina Edited by: Erasmo Garcia
Ochoa

2
5
2.4.4 Operation of the starter motor

When the driver puts the switch in contact to start the MCI, the iron core
inside the contactor moves, thus closing at end 1 and in the direct circuit between
the battery and the electric motor. While at end 2, it moves to the fork, which in
turn pushes the drive pinion until it comes into contact with the flywheel. Fig. 24

Figure 24. Starter motor in rest position Source: Charging and starting system, 2012,
Margarita Calsina Edited by: Erasmo Garcia Ochoa

When the driver stops operating the switch (A), the iron core returns to the
rest position and with it the fork (2), while the battery-electric motor circuit remains
open. Fig. 25

Figure 25. Starter motor in operating position Source: Charging and starting system,
2012, Margarita Calsina Edited by: Erasmo Garcia Ochoa
CHAPTER III

TRAINING BENCH DESIGN

Design is to meet a specific need or solve a problem. If the result of

creating something physically real, then the product must be functional, safe,

2
6
reliable and useful.13

Structural elements must withstand certain loads applied transversely to

each axis. In a generic beam with all the forces in the same plane, three
components of the internal forces will appear in each section, axial N, shear V and
bending moment M.

3.1 Bending stress calculations

Simple and combined bending stresses are obtained when a pair of forces are
applied to a body that are acting perpendicularly to its longitudinal axis, and this
would cause a rotation of each cross section with respect to the immediate ones.
Fig. 26

Figure 26. Bending stress forces Source: Erasmo Garcia Ochoa

13 Shigley's Design, Design in Mechanical Engineering

2
7
Bending stress formula

W= mg

m
= Gravity s2

W = Weight (kg)

Data (alternator and starter motor test bench measurements)

a = 70 cm ~ 700 mm
= 64 kg
g = 9.8im
s2

Resolution

w = (64)(9.81)

f = 1.5 (W)(f) = (627.84^(1.5) = f = Safety factor1'4

941.76 N = F ~ Force

Shear and bending stress

ZF = 0 1M = 0
0 = F-R1-R2 YMA = R2(A + b)
F = R± + R2 YMB = R1(A + b)
F = 2R -R=R,
941.76 = 2R
R = 470.88 N

14
The safety coefficient (also known as the safety factor) is the quotient between the
calculated value of the maximum capacity of a system and the value of the actual
expected requirement to which it will be subjected.

2
8
3.2. Electric motor installation calculation

The bases of the electric motor, where the motor will be placed, must be flat
and, if possible, free of vibrations. The motor bases can be fixed or elastic. 15 Fig.
27

Figure 27. Dimensions to be taken from the base of an electric

motor Source: Electric Machines, 2012, Orrego Edited by:
Erasmo Garcia Ochoa

The stresses on the base can be calculated using the following

equations:

(4. ^max)
F1 = +0.5.m.g+ (TO)

(4. ^max)
F2 = +0.5.mg— (TO)

2
9
 Where:

F1 and F2: Force of the feet on the base (N).

g: Acceleration of gravity (9.81 2).
m: Engine mass (in Kg).
Cmax: Maximum engine torque (Nm).
A: Obtained from the dimensional drawing of the engine (m)

Figure 28. Effort on the base of the engine Source: Electric Machines, 2012, Orrego
Edited by: Erasmo Garcia Ochoa
Development

m (4.1492 Nm}
1
^^ ^ ^0.5 .220 .9.81
s2
o2 +
(0.15 m)

^^ ^ 40,859 N

m (4.1492 Nm)

3
0
 ^^ ^ ^0.5 .220 .9.81
s2
^
(0.15 m)

^^ ^ 38.701 N

1.3. Selection of materials

The materials used to make the structure of the model will be detailed
below. Board. 1 and 2

Table 1. Materials
Cant Description
2 Steel plates 3m*1m
2 1” * 1” square tubes
4 Garruchas
20 Steel screws
5 6011 Welding Pounds
20 Rivets
1 Gallon of navy blue paint
3 Gallons of thinner
1 Liter of putty
5 Sanding boards
2 Door handle set
Edited by: Erasmo Garcia Ochoa

Table 2. Tools
Cant Description
1 Welding machine
1 Grinder
1 Drill
1 Cutting disc 4 ½” 1/16

3
1
 5 Sandpaper #80
15 Sandpaper #600
1 Air compressor
Edited by: Erasmo Garcia Ochoa

In this project, high-strength materials were used, because the elements to

be installed had a considerable weight, and required stable materials for the use of
the electric motor since this would provide vibrations to the entire training bench
and with these materials and robust structure we would prevent the project from
having vibrations not required for it. For the reduction, a band with a length of 1 m
was used.

1.4. Training bench structure design

The design of the training bench employed an area of 70 x 60 cm, in which a

special area is intended for positioning the starter motor and alternator as shown in
Fig. 29.

3
2
 The layout of the spaces where the alternator and starter motor are located
is an efficiently chosen area. The control panel needs to withstand extreme
working conditions such as sudden movement, high working temperature, work
ergonomics, this part is very important because at the time of practice the panel is
comfortable to observe the measurement parameters and its operation since this
panel has an inclination of 30 °. This makes it visibly comfortable and the
operating switches have indicator lights to avoid mistakes when carrying out the
exercises. Fig. 30

3
3
 CHAPTER IV

CONSTRUCTION OF THE TRAINING BENCH

4.1 Indicator light panel

To install the indicator light panel, the acrylic protection was removed and then
the vinyl was glued with the design shown in the following figure 31.

Figure 31. Indicator light panel Source: Erasmo Garcia Ochoa

Figure 30. Views of the bank

designSource: Erasmo Garcia Ochoa

3
4
 To install the elements on the acrylic, the acrylic was first drilled, as this
procedure is easier without the vinyl being glued first, since if it is in place it could
be damaged and it would be a waste of time. Fig. 32

4.2 Installing training bench components

4.2.1 Starter motor installation

The starter motor has 2 current inputs which are the direct positive of the
battery and the other input is the switch signal put into contact at the time of
starting. Fig. 33

Source: Erasmo Garcia Ochoa

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5
 For the selection of the starter motor, it was considered that it has all the
mechanical elements for educational purposes and data from the manufacturer of
the same. Its data is reflected in a test bench with all the variables that are applied
when testing the starter motor. Board. 3
Table 3. Starter motor data
Starter Type Toyota
Starter Model Stout
Rated Power 1.40 KW
Rated Voltage 12.00 V
Max Power 1.57 KW
Max Torque 21 Nm
Max Ampere 591 Amp
Edited by: Erasmo Garcia Ochoa

For the final installation on the training bench, the starter motor base was
fixed to its bases with a welding machine to avoid vibrations. Fig.34

3
6
4.2.2 Alternator installation

For the installation of the alternator, the position that it should have with
respect to the electric motor was taken into account since these two elements
must be completely aligned to prevent the belt or channel strip from coming loose
when the electric motor is activated. Fig. 35

This alternator was selected because it incorporates one of the regulators

see Fig. 36. most efficient on the market, which is the Mitsubishi brand, in the
following table you will see how it behaves on the alternator test bench.

The alternator has one terminal (B+) and the connector for the regulator.

36, Table.4

Fig.
Table 4. Alternator Data

3
7
 Max Alternator Output Amp 97.3
Max Output Power Watts 1313.55
Alternator Turn On Speed RPM 1147
Speed @ 0 Amp RPM 1197
Voltage Regulator set point Volts 14.75
Edited by: Erasmo Garcia Ochoa

The parameters used in the installation are that the base of the alternator
must be very elastic so that when placing it, it does not transmit the vibrations of
the alternator generated by its use to the training bench since, as is understood,
vibrations are the number one cause of damage to fixed elements. With this
knowledge, it was placed taking into account that the alternator adjuster must be
adjustable so that, when it is required to disassemble it for a check, it is in a very
comfortable and safe manner.

The band or strap must be suitable for the adjustment, so a band was
chosen that meets these requirements. The band that was chosen is a (5PK 1260)
which is a channel band suitable for the alternator of the training bench. Fig. 37

3
8
 For the protection of users, a protector was implemented for the
band Figure 38. Alternator with its
belt protectionSource: Erasmo Garcia Ochoa
for
avoid accidents. Fig. 38
4.3.3 Electric motor control circuit installation

For the installation of the circuit, industrial electrical control elements were
used, such as breakers, contactors, fuses, multiple sockets, and industrial
electrical plugs. These elements will be detailed below:

Figure 37. Alternator beltSource

: Erasmo Garcia Ochoa

3
9
 Fuses: This element is of utmost importance because when there is an
overload, they will blow and completely protect the system. In these fuses, 30 amp
industrial fuses were used. Fig. 39

Figure 40. Breakers

Source: http://www.schneider-electric.com/
Edited by: Erasmo Garcia Ochoa
Breakers: This element is of utmost importance when there is a short circuit
that the fuses have not detected. Fig. 40

Contactor (Auxiliary contactor): This element acts as an automotive relay

but with the capacity to operate with high voltages, this element is of utmost
importance because it controls the On and Off buttons for starting the electric
motor. Fig. 41
Figure 39. Industrial rifles
Source: http://www.camsco.com.tw/spa/fuse-link-base/RT-18-32A.
htmlEdited by: Erasmo Garcia Ochoa

4
0
 Figure 42. Industrial plug
Source: www.directindustry.
esEdited by: Erasmo Garcia Ochoa

Industrial plug: This type of connector is very important since it is very safe
as it acts as a safety lock when connecting it. Fig. 42

Figure 41. Contactor

For the Source: http://www.siemens.com.mx/ electrical installation
Edited by: Erasmo Garcia Ochoa
#10 cable was used for the phases
mains and cable #16 (3 to 1.8 Amp). For the main panel control, the correct
electrical connection can be seen in the diagram. Fig. 43

4
1
 MAIN
BREAKER

FUSES

Figure 44. Control pressure

gauges Source: Erasmo Garcia
Ochoa
To control the amperage and voltage of the power electrical system,
pressure gauges were implemented to monitor the electric motor when the
alternator is working correctly. Fig. 44

Figure 43. Electrical installation Source: Erasmo Garcia Ochoa

4
2
The general diagram of the power electrical circuit was made with European
standards for better knowledge since, with these standards we operate at a
national level. Fig. 45
4.3.4 Halogen electrical installation

In this section we will detail how the electrical installation of the control for
the 12 volt system was carried out; for the training bench this part is of utmost
importance.

The first part was the installation of the halogens, with which the alternator
will be charged at the time of operation. H4 60/55 W halogen was used and a
terminal block for its safe positioning at the back of the training bench. Fig. 46

Figure 45. Electrical diagram of 220 V

powerSource: Erasmo Garcia Ochoa

4
5
 Figure 46. Installation of
H4 halogensSource: Erasmo Garcia Ochoa

For positioning, it must be taken into account that halogens have high
luminosity, and therefore also emit radiant heat that can melt any plastic element
near them, which is why their position was made between two beams to avoid
having close contact with the acrylic of the main panel. Fig. 47, 48

4
6
Figure 47. Positioning of halogen
H4Source: Erasmo Garcia Ochoa

4
7
Figure 48. Electrical diagram of halogen
H4Source: Erasmo Garcia Ochoa

4
8
4.3.5 12v control installation

In this section, the control installation of the entire 12 V system will be

carried out. For this, contact relays, switches, sockets, and battery terminals were
used. Fig. 49

Figure 49. Control relays Source: Erasmo Garcia Ochoa

For the general connection, terminal blocks were used to take positive and
negative currents, which are located on the back of the bench.

The measuring instruments used are: Voltmeter, ammeter, charge indicator

and test leads.

4
9
 For the installation of the electrical system, terminal blocks were used for the
positive and negative sides. Fig. 50

Figure 50. Terminal blocks for electrical system Source: Erasmo Garcia Ochoa

In the installation, the main control system goes through a main relay that,
for its operation, is activated by means of a negative signal to avoid high
amperages in the conductors, since the relay could absorb these amperages
without any difficulty. And the relay also has the function of sending positive current
to the switches to turn on their lights, and to indicate when the switches are on. Fig.
51

Figure 51: Control panel Source: Erasmo Garcia Ochoa

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The electrical diagram specifies the connection on the training bench. Fig. 52

Figure 52. Diagram for 12v electrical system Source: Erasmo Garcia Ochoa
• 12v power supply

To supply power to the 12v electrical system, a battery/starter was used

which supplies 12.70 volts. Fig. 53. To the entire system, but since this equipment
can be electrically charged with 110 volt alternating current, to make this
connection a phase and a neutral were taken for charging as specified in the
electrical diagram in figure 45.

5
1
Figure 53. Battery / Starter of the 12 volt electrical system Source: Erasmo Garcia Ochoa
CHAPTER V

FUNCTIONAL TESTS

5.1 Alternator Test

Alternators are classified into alternators with built-in regulators and external
regulators, which also have the same function, which is to supply energy to the
battery.

The tests that can be performed on the alternator are:

• Using a clamp meter, the alternator amps or the charging system

consumption are measured. Fig. 54

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2
Figure 54. Alternator test with current clampSource
: Erasmo Garcia Ochoa

5
3
 • Using a voltmeter, the voltages generated by the alternator are measured.
Fig. 55

Figure 55. Alternator test with voltmeter Source: Erasmo Garcia Ochoa

Table of measured parameters of amperes and voltages.

Table 5. Measurement parameter table

13.5 v 14.5

Edited by: Erasmo Garcia Ochoa

5.2 Testing the starter motor

Starter motors can be diagnosed by voltage drops at start-up or the amps

drawn by the starter motor to the battery.

5
4
 CHAPTER VI

PREPARATION OF THE MAINTENANCE MANUAL AND

TRAINING BENCH OPERATION

6.1 Developing a teacher's guide

Introduction
The starter motor and alternator training bench is very useful for students, since
they will learn the correct operation of the aforementioned systems, they will be
able to measure, compare, and take samples of shots on the training bench.

Goals

• Analyze each of the systems installed on the training bench.

• Induce the student to the practical experimental part to reinforce his

knowledge about the functioning of the training bench systems.

Safety information
ATTENTION!

• Check that everything is in good condition before operation.

• Use apron, gloves, safety boots.
• Identify components before use.
• Check that the alternator belt has its protection.
• Do not manipulate the control panels unnecessarily.

General
ATTENTION!

This written manual contains instructions for the operation and maintenance of the
project.

5
5
• The bank needs proper cleaning.

• The bench must be cleaned without wet cloths as they can act as an energy
conductor and could electrocute the operator.

• The project has an electric motor that works with a belt that drives the
alternator. If you are going to perform maintenance on these elements, it is
recommended that you make sure that the main stop button is activated,
since this allows the total cut-off of the current, because if it is not done, the
electric motor may be activated involuntarily and could dismember a finger
or a hand.

• When taking measurements on the alternator, avoid the cables making

contact with the project because this could seriously damage the alternator
regulator, since it is very sensitive to currents produced by short circuits.

• Do not introduce foreign objects into the test lead terminals.

• Operate the switches on the main panel and control board carefully as they
are not very heavy work elements.

• Remove the plug from the electrical socket very carefully, avoiding contact
with its tips.

• Always keep door locks lubricated to prevent rust from attacking their parts
and thus avoiding further deterioration.

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6.2 Developing practical guides for students

DELEDUADOR INTERNATIONAL
UIDE
UNNVERSOAD NTERNATIONM on
ECUADOR
UNIVERSITY
FACULTY OF AUTOMOTIVE

MECHANICS ENGINEERINGGUAYAQUIL SITE

March 2016 – August 2016

SUBJECT CODE LEVEL DATE TIME

1h.

LABORATORY OR WORKSHOP PRACTICE NO. NAME OF THE PRACTICE

Automotive Workshop Center Induction to measuring instruments.

1. PURPOSE

• Know and interpret measuring instruments.

2. OBJECTIVES (Competencies)

• Understand how measurements are taken with diagnostic equipment.

3. THEORETICAL BASIS
Main measurements of the charging and starting system. Operation of the
systems.
4. RESOURCES
TEAMS MATERIALS SUPPLIES
Training bench for taking Computer for practice
measurements

5. OUTLINE

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6. PROCEDURE

• Investigate the functions of the measuring instruments used

• Investigate concepts of voltage, resistance, current and frequency.
• Describe the measurements that can be made on the model.
• Take measurements with the multimeter
• Performing measurements with the Oscilloscope
• Analyze Oscillograms.
• Submit a corresponding report

7. CALCULATIONS AND RESULTS

8. CONCLUSIONS

9. LITERATURE

NOTE: Please include the digital signature.

STUDENT COORDINATOR OF IN CHARGE OF
LABORATORY LABORATORY

5
8
 DELEDUADOR INTERNATIONAL
UIDE
UNNVERSOAD NTERNATIONM on
ECUADOR
UNIVERSITY
FACULTY OF AUTOMOTIVE

MECHANICS ENGINEERINGGUAYAQUIL SITE

March 2016 – August 2016

SUBJECT CODE LEVEL DATE TIME

1h.

LABORATORY OR WORKSHOP PRACTICE NO. NAME OF THE PRACTICE

Automotive Workshop Center Induction to the charging system.

1. PURPOSE

• Understanding how the alternator works.

2. OBJECTIVES (Competencies)

• Understand how the alternator works and how measurements are taken with
diagnostic equipment.
• Graph the measurements taken.

3. THEORETICAL BASIS
Main measurements of the charging and starting system. Operation of the
systems.
4. RESOURCES
TEAMS MATERIALS SUPPLIES
Training bench for taking Computer for practice
measurements

5. OUTLINE

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6. PROCEDURE

• Investigate the parts and functions of the alternator

• Research the types of alternators and regulators
• Researching the selection of an alternator for a vehicle
• Research concepts of voltage, amps.
• Describe the measurements that can be made on the model.
• Take measurements with the multimeter
7. CALCULATIONS AND RESULTS

CONCLUSIONS

LITERATURE

NOTE: Please include the digital signature.

STUDENT COORDINATOR OF IN CHARGE OF
LABORATORY LABORATORY

6
0
 DELEDUADOR INTERNATIONAL
UNIVERSITY
FACULTY OF AUTOMOTIVE

MECHANICS ENGINEERINGGUAYAQUIL SITE

March 2016 – August 2016

SUBJECT CODE LEVEL DATE TIME

1h.

LABORATORY OR WORKSHOP PRACTICE NO. NAME OF THE PRACTICE

Automotive Workshop Center Induction to the starting system.

1. PURPOSE

• Understanding how the starter motor works.

2. OBJECTIVES (Competencies)

• Understand how the starter motor works and how measurements are taken with
diagnostic equipment.
• Graph the measurements taken.
3. THEORETICAL BASIS
Main measurements of the charging and starting system. Operation of the
systems.
4. RESOURCES
TEAMS MATERIALS SUPPLIES
Training bench for taking Computer for practice
measurements

5. OUTLINE

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6. PROCEDURE
• Investigate the parts and functions of the starter motor
• Research on 24v voltage starter motors
• Research and compare starter motor performance curves
• Research concepts of voltage, amps.
• Describe the measurements that can be made on the model.
• Take measurements with the multimeter
• Performing measurements with the Oscilloscope
• Submit a corresponding report.

7. CALCULATIONS AND RESULTS

CONCLUSIONS

LITERATURE

NOTE: Please include the digital signature.

STUDENT COORDINATOR OF IN CHARGE OF
LABORATORY LABORATORY

6
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 CHAPTER VII

CONCLUSIONS AND RECOMMENDATIONS

7.1 Conclusions

• The starter motor and alternator training bench will allow automotive
mechanical engineering students to appreciate the operation of the
charging and starting systems in full use and with their proper loads to their
different systems.

• The knowledge acquired in this project will provide the student with solid
knowledge of new technological trends regarding charging and starting
systems, and how these systems contribute to the environment.

• Practice guides were implemented in the laboratory of the International

University of Ecuador for the correct use of the training bench and they
describe the processes and steps to follow for the student's use.

• The design began with an exhaustive analysis to ensure that the training
bench is as comfortable as possible for practice and that the distribution of
its parts is as easy as possible for the student to detect.

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7.2 Recommendations

• Before using the training bench, check that the alternator belt is in position
and is not damaged.
• Check the project connections before starting up the equipment.

• Practices on the training bench would be carried out as long as the student
had reviewed the operation and maintenance manual.

• Do not turn on the main panel lights for long periods as this could damage
the battery.
• Never activate the 110 volt battery charging switch on the control panel
when the alternator is running as this could cause severe alternator
damage.

• Check that the battery/starter is in good condition before turning on the

training bench.

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 Annexes

Annex 1 – Training bench design plans.

Side view

160 cm

70 cm

Front view

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Appendix 2 – Alternator technical sheet.

ALTERNATOR TYPE: 23100-50Y09

P/N: 150828
S/N: 0167

Test results table:

Max alternator output Amps 97.3
Max output power watts 1313.55
Alternator turn on speed RPM 1147
Speed @ 0amp RPM 1197
Voltage regulator set point Volts 14.75
Load characteristic Volts 0.00
Speed characteristics Volts 0.00

Output current table:

1500 RPM output current Amps 28.2
1750 RPM output current Amps 44.2
2000 RPM output current Amps 57.6
2500 RPM output current Amps 73.8
3000 RPM output current Amps 82.7
4000 RPM output current Amps 90.9
5000 RPM output current Amps 95.1
6000 RPM output current Amps 97.3
Output tested @ 13.5 V

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 STARTER TYPE: MITSUBISHI ax A
STARTER MODEL: TOYOTA
p
9 p
RATED POWER: 1.40 kW
e
RATED VOLTAGE: 12.00 V 00 n
MAX POWER: 1.57 kW di
MAX TORQUE: 21 Nm 00 x
MAX AMPERE: 591 Amp 3
STARTER TEST CURRENT MAX 591
–
DIRECTION CW
St
STARTER TEST
STARTER TEST POWER MAXStarter 1569,00
EC ar
35,00
STARTER TEST 0 R IPPLE CUR RENT 16 55

30,00
te
STARTER TEST
500 T ORCH MA 21,21
r
25,00
1000
TEST STEP # 0 AT 1200 RPM
1500 S TARTER C RRENT 362 124 526 m
20,00
TEST STEP # 0 A2T0102000
RPM
S TARTER P WER 1497,82 1085, 00 ot
15,00
TEST STEP # 0 A2T5102000
RPM
S TARTER
TO
7,500 17,5
or
10,00
TEST STEP # 0 A3T0102000
RPM TARTER
TO
0,0330 0,020 1 te
5,00
c
TEST STEP # 1 A3T590800RPM RRE
S TARTER C NT 445 209 581

0,00
4000
TEST STEP # 1 AT 980 RPM
S TARTER P WER 1565,90 1124, 00
h
4500
ni
TEST STEP # 1 AT 980 RPM TARTER
S TO RQUE 15,281 10,70 0 20,6 00
5000
TEST STEP # 1 AT 980 RPM
1 S TART2ER RQU3E CO
STA4N 05,0343 60,020 2 7 8 9 10
TO
T STEP # 2CAuT TA2RT0E9 RR3E6N2T T
TES rMrAeXnPOtW
ER1 S RC
445 446666 ! 81 5 91
T STEP # 2kAWT MAX
2
E1R08 5S TA1R1TE2
TES POW R4P
W1E3 1498 1155669 1 5613 00

T STEP # 2RAPTMMAX
R25
TA9RT3E0 E1ED193
5,00 925,
TES POW
ER5 S R SP
1703 298370 4 5854
1703

T STEP # 2VAT MAX

4 5S
4 93
TES 1ER2, T1AR1T,E R1Q0 9,25 16,125 9,400 28,7 00
POW

T STEP # 2NAmT MAX

3 0R0TO U,E54
TES ER7.5 S TAR9T,E R1QU0E,7 S1TA1N,T 105,0,3 1 60,,1 3 1 7,5 2 0,6 21,2 28,7
POW
4R TO CO 9 340 020

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 LITERATURE

• Bosch, R. (2000). Alternators Technical Instruction. In Alternators

Technical Instruction

• Fleta, M. C. (2012). Charging and Starting Systems. Spain: MacMillan.

• Nisbett, R. G. (2011). Shigley Mechanical Engineering Design. Mexico: Mc

Graw Hill.

• Orrego, J. J. (2012). Electric Machines. Spain: Auditorium.

• Techbook, H. (2012). Automotive Electricity Manual. Mexico: Haynes.

• Vicente, M. d. (2011). AUTOMOBILE ELECTRICITY I Power supply and

starting. Spain: Ceac.

• Oscar B, Joan A (2011). ELECTRICAL, SECURITY AND COMFORT

SYSTEMS. Spain: Paraninfo.

• Ase test preparation (2012) ELECTRICAL/ELECTRONIC SYSTEMS.

United States: Delmar

• D. Hermogenes gil (2000) PRACTICAL AUTOMOBILE MANUAL. Spain:

MMXI/MMXII

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