YEAR OF UNITY, PAL, AND DEVELOPMENT.

INSTITUTE SUPERIOR
TECHNOLOGICAL PRIVATE

CIRO ALEGRIA

WORK OF INNOVATION
Y/OR IMPROVEMENT IN THE PROCESS OF
PRODUCTION OR SERVICE IN THE COMPANY
TITLE TEST BANK OF
100A SCANIA ALTERNATOR
SERIES F K N.
COMPANY VALLEJOS S.A.C SELF SERVICE

STUDENT EVER JHOVANNY CRUZ TAPULLIMA.

CAREER AUTOMOTIVE MECHATRONICS.

INSTRUCTOR RODANY RUIZ RENGIFO.

PRIVATE HIGHER TECHNICAL INSTITUTE *CIRO ALEGRIA*

DEDICATION

To God for guiding my steps and giving me the

forces, the understanding and the will that me

has allowed me to complete my technical degree which for

vocation I chose. To my dear parents for

provide me with all your support and understanding, that you

they encouraged me to achieve my goals like

professional.

EVER JHOVANNY CRUZ TAPULLIMA

THANK YOU

2
PRIVATE TECHNOLOGICAL HIGHER INSTITUTE *CIRO ALEGRIA*

I want to give thanks to Almighty God

for giving me life, for health and the strength to
achieve my goals.

To my parents for their unconditional support

that made it possible for me to realize myself as a
successful professional. And also thank
relatives for that moral and economic support that
they provided me.

I want to thank all my instructors.

who shared their knowledge, in order to
develop myself within the work environment.

I also want to thank Mr. CESAR.

VALLEJOS TAPULLIMA. for providing me with the
opportunity of to perform my practices
professionals in your company AUTO SERVICES
VALLEJOS S.A.C.

EVER JHOVANNY CRUZ TAPULLIMA

INDEX
Page
Cover.........................................................................1.

Dedication

3
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Acknowledgment ………………………………………………………………….…...3.

Index................................................................................4.

Presentation .......................... 7.
Project name.................................................................8.

Introduction..........................................................9.

Background…………………………………………………………………………..10.

Objectives.................................................11.
General objective..........................................................11.

Specific objectives…………………………………………………………….…….11.
Description of the project and/or improvement............................12.

Methodology................................................................................15.
Project design........................................................................15.

Description of the construction.............................................................................16.

Design plans............................................................17.

Base description of the alternator support...........................18.

View of the mounting base on one side of the alternator..............................20.

Description of components used.................................................22.

Technological concepts

Speed variator………………………………………………………………….25.

Electric motor……………..........................................................................…….29.

Principle of operation of the electric motor.................................30.

Guard motor..............................................................31.

Measuring instruments.......................................................32.

Tachometer.........................................................35.

Electric conductors………………………………………………………………36.

Terminals……………………………………37.

Belt transmission……………………………………………………………..38.

4
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Trapezoidal belts............................................................39.

Pulleys………………………………………………………………………………….41.
220v electrical circuit.............................................................42.

Alternator……………………………………………………………………...…..43.
Electric power generation in the vehicle……………………..……………44.
Influential magnitudes...................................................45.

Basic principles.................................................................47.

Electrodynamic principle…………………………………………………………...48.

Principle of three-phase alternator…………………………………………………….49.

Rectification of alternating current.................................................50.

Circuit for three-phase current rectification................................51.

Return current blockage……………………………………………...…..54.

Rectifier diodes..........................................................54.

Three-phase alternator circuit………………………………………………………55.

Because of pre-excitation...
Alternator control lamp...................................................57.

Excitation current.................................................................58.

Alternator current circuit……………………………………….………...59.

Voltage regulation.............................................................61.

Principle of voltage regulation ........................................................... 61.

Structure of the alternator.........................................................63.

Parts of an alternator............................................................64.
Alternator versions..............................................................65.

Sizing criteria…………………………………………………...….65.

Data and construction sizes..........................................................66.

Compact alternators series B…………………………………………………...…67.

5
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Structure of the alternator of series B.................................69.

Security concepts...............................................................70.

Personal protective equipment....................................................71.

Environmental concepts............................................................76.

The 5s.............................................................77.

OHSAS........................................................................79.

International standard 14001

Environmental risks………………………………………………………………...…81.

Workshop plans, schematics/diagrams ……………………...……82.

Work area distribution plans..............................................82.

Location plans of the workshop..............................................................83.

Administrative aspects…………………………………………………………..….84.

Activity schedule………………………………………………...…………86.

Conclusions.................................................................87.

Bibliography.............................................................88.

6
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

ESTUDIANTE: EVER JHOVANNY CRUZ TAPULLLIMA

COD: 00878618

PROFESSIONAL CAREER: AUTOMOTIVE MECHATRONICS.

CICLO: III

7
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

PROJECT NAME
100A SCANIA ALTERNATOR TEST BENCH
SERIES F K N.

COMPANY AUTO SERVICES 'VALLEJOS'

RUC 20606200413

AREA HEAD BERNILLA CAVE USBARDO

SECTION Automotive electricity.

INTRODUCTION

8
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

In the current project of innovation and/or improvement in the production process or

service in the company, complying with the directives' provisions
established by the PRIVATE HIGHER TECHNOLOGICAL INSTITUTE 'CIRO
"JOY", the present project developed for the SERVICE company
TECHNICIANS 'MECHANICAL - ELECTRIC', AUTO SERVICE 'VALLEJOS' S.A.C
elaborated in the current year, as a student who is in the III CYCLE, it is
the formulation of a project for 'Proposal for the implementation of a bank of
test for alternator

The present innovation project achieves better maneuverability of the

mechanisms within the company 'AUTOSERVICIOS VALLEJOS S.A.C.'
providing better electric service for the transport units. And allowing
carry out verification tests of the functionality of the accessories of the
vehicles such as alternators since these auxiliary vehicle equipment
they represent a problem when it comes to verifying their correct functioning.

This project summarizes the proposal to develop a team to carry out

functionality verification tests on 24V 100A alternators.

The designed bank allows for the quick setup of the equipment to be analyzed, the visualization

from the test parameters (voltage and current) and the variation of conditions of
speed (RPM) at which the component will be subjected. The bench allows
record the voltage and current generated by the alternator, comparing them by the
data provided by the manufacturer's technical specifications.

The plans of the equipment are included in that content, as well as those of the
accessories designed and/or used to achieve this objective. This includes
electrical diagram of the designed equipment as well as information
provided by the manufacturer of the equipment used in this bank.

9
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

BACKGROUND
In the workshop 'AUTOSERVICE VALLLEJOS S.A.C.', it lacks a team of
alternator test, which makes it difficult to verify its proper functioning.
component.

Therefore, we consider it necessary to carry out the project 'PROPOSAL'

IMPLEMENTATION OF AN ALTERNATOR TEST BENCH
100A SCANIA SERIES F K N", desiring to carry out a job in such a way
eficiente.

And thus make use of the time that was previously spent taking it to another place.

component to ensure its operation is effective, to carry out others

things inside the workshop.

The planning and development of this innovation project is carried out so that
technicians and apprentices increase productivity and quality of work within
from the company using less time, since this inconvenience makes it difficult for the
work and the generation of income within the workshop, which will depend on this
project to improve productivity within the company.

10
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

PROJECT OBJECTIVES
3. General objective.
Proposal for the implementation of a 100A alternator test bench
SCANIA series F K N P G R the company 'AUTOSERVICE VALLEJOS
S.A.C.

3.1 Specific objectives.

Ensure quality work and greater safety when performing
the diagnosis of the component.

Increase productivity, facilitate operational processes,

ensuring quality and efficiency in work, with greater safety,
environmental care and the highest quality of service provided by the
company.

Reduce the diagnostic processing time for the parameters to be taken.

of the correct functioning of the equipment.

11
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

DESCRIPTION OF THE INNOVATION PROJECT AND/OR

IMPROVEMENT.
Description.
The proposal for the implementation of an ALTERNATOR TEST BANK
24V 100A. It is a very compact and easy-to-handle equipment with availability.
for people with knowledge of automotive electricity.

This project will allow us to analyze an alternator and have values (voltage and
operating amperage) of the component. It will also allow for comparison
values according to the manufacturer's technical specifications. And display
values of (voltage and current), consists of a speed variator which
similar to the vehicle's engine, according to the different speeds that it may be
subjected the engine.

Brands.

SCANIA series (F, K, N, P, G, R)

Materials.

Black iron sheet.

1" square iron tube
Iron plate A6
Cable AWG 12.
Automotive cable AWG14.
Hexagonal bolts M12 X 40 continuous thread.
16.5mm threaded bolts.
Cable 1.0.
Tuboflex 1".
Insulating tape.
AWS E6011 electrodes 1/8" 3.20mm.
Bolts ¼ x 1.
2hp electric motor 220V.

12
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

250 amp motor guard.

2hp 220V SIEMENS speed variator.
Pulley.
V-shaped trapezoidal belt.
LCD ammeter and voltmeter 4.5 30 DC.
Tachometer 400 to 4000 RPM.
Pilot lamp.

Feature.

Power supply 220V.

Allow the variation of speed (RPM) of the electric motor simulating to
vehicle.
Compact design 900 x 800 mm.
Digital measuring instruments.
Exclusive for small places.
Allows easy assembly of the component to be tested.

Application

It can be applied in automotive electrical workshops or laboratories.

try these components.

Mode of use.

Connect the plug to the 220V power supply.

Mount the alternator on its mounting base.
Place the belt on the pulleys (motor, alternator)
Connect the positive and negative cables to the 24V batteries accordingly.
from the tension of the component.

Connect the power to the alternator (B-, B+, D+), if the component
will have a revolution counter connect the connector W.
Tighten the alternator bolts securely to test.
Turn the motor guard button to the OFF position, on.

13
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Turn on the speed variator, check its operation.

Vary the motor speed, key, check the component load.

Turn off the RPM speed controller.
Turn off the motor guard position ON.
Disconnect the power plug.

Installation.

Connect the plug to the power supply voltage 220V.

Turn the motor guard button to the OFF position, on.
Turn on the RPM speed controller, key .
Program the speed variator RPMs that you need.
Test functionality.
Apagar (variador, guarda motor).

Maintenance.

Check the status of the connection cables.

Check the fastening bolts. Of components.

Precautions.

Be careful to let go of the keys at the moment of connecting the terminals

battery.
Avoid getting the equipment wet.

14
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Methodology.

Project design.

The present project of PROPOSAL FOR THE IMPLEMENTATION OF A BANK

TEST OF 24V 100A ALTERNATOR was done according to the
needs of the workshop AUTOSERVICIOS 'VALLEJOS' S.A.C for the area of
automotive electricity, in order to carry out a diagnosis in such a way
efficiently and reducing the time it takes to execute the operation. Likewise
check the proper functioning of the alternators.

Design of the alternator test bench.

A set of designs was taken as a model, and it has parameters of

applicable measures to said component. It has a high structure.
design in the placement of its components, respecting safety standards
in the work on the quality standard and assembly of its components.

I researched online the application of the alternator tester.

having results from the existence of such a component used in the industry
automotive. These diagnostic equipment that are not only expensive and
Difficult to operate are too large, making transportation difficult.

The bank design must specify its stipulated dimensions.

the materials used for its construction will be described,
electrical components to be used as protection mechanisms for the equipment and
measurement of the components that we will analyze.

The function of the alternator tester is to allow for accurate diagnosis.

of its correct functioning and verify the load values. We will measure voltage
amperage

15
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Description of construction.
For the construction of the test bench structure, the following was used,
existing materials in the market. We use square iron tube
sweet, since it will not withstand much weight. Electrodes were also used to
weld the tubes to ensure the strength of the plates that
we will use to cover the sides. To cover the components
we will use black iron sheets, the platform will carry a plate of
metal of 6mm. To support the motor and will serve as a base. The bench
will have enough space to accommodate the elements that constitute the
equipment, such as electric motor, SIEMENS 2hp frequency inverter
220V, motor guard, tachometer, measuring instruments.
We will now show figures of the metal structure.
The graph shows the isometric views:
Front view.
Side view.
Top view.

16
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig.1 Front view

17
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 2 side view

Fig.3 Top view

18
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Alternator mounting base.

The alternator mounting base was presented as a problem due to the

difficulty due to the design of these materials that exist in the market. Therefore
the reason was the need to investigate in order to acquire an idea, to be able to
design the component, thus the need to design the database is presented
of fastening. The design is based on the actual form of fastening of the alternator in the
vehicle. For this design, we used a sheet of A36 iron and the others

19
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

components were adapted from the remaining scraps of the other profiles, (tube
iron square and iron platinum), leftovers from the structure.

The figures are shown below.

Top view of the mounting base.

Fig. 4 Top view mounting plate.

20
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 5 views of the piece that holds one side of the alternator.

21
CIRO ALEGRIA PRIVATE HIGHER TECHNOLOGICAL INSTITUTE

Fig5.2 view in 3D. upper support base

22
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

THEORETICAL FRAMEWORK

Test bench

There are different types of testing classes for alternators, these

they differ in their capabilities such as control, maneuverability, traction,
load capacity, stability, and efficiency.

TECHNOLOGICAL CONCEPTS
Frequency converter

Frequency converters are systems used for speed control.

rotational speed of an alternating current motor. A frequency variator is
voltage sources of a variable speed drive, as they carry a frequency control of
feeding, which is supplied by a motor.

Another way in which frequency converters are known is as Drivers.

either adjustable frequency drive (AFD) or AC, VVVF (variable voltage variable frequency)
of frequency), micro drivers or inverters; this largely depends on the voltage.
that it is handled.

23
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 7 frequency converter circuit.

How does a frequency converter work?

The equipment is powered with an alternating current (AC) voltage, the equipment first
convert the AC to direct current (DC) through a rectifier bridge
(diodes or SCRs), this voltage is filtered by an internal bank of capacitors, with
the end of smoothing the rectified voltage and reducing the emission of variations in the
signal; subsequently in the investment stage, which is composed of
transistors (IGBT), which turn on and off in a specific sequence
(sending pulses) to generate a square wave of DC voltage at
a constant frequency and its average value has the sine wave form of
the frequency applied to the motor.

Function

The frequency drives see fig.2, handle the frequency found in the field.
rotor electric. The rotor is responsible for controlling the speed, torque,
direction and power of the motor. Six diodes, which are the conductors of electricity
in one direction and are found in the converter, they are the entry section to the
variator. The negative semicircles of the waveforms are converted into
positive cycles. The waveform then passes through the inverter, where the DC voltage
it transforms into AC voltage. Most modern inverters create a
AC voltage and variable frequency. The control board of the variator determines the
carrier frequency establishing how often the control circuits
they turn on and off. This carrier frequency determines how fast or
slowly operates a machine.

24
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Benefits

Frequency converters are used as components in a variety of

different systems such as ventilation systems, pumps, belts
carriers and machine tools. These variators are essential for
equipment that must operate at different speeds. With the systems of

Ventilation, the variable frequency generates the benefit of saving energy when using
only the necessary one to obtain appropriate ventilation.

Types

The types of frequency converters are constant voltage, constant current

constant and the converter cycle. With constant voltage converters, the voltage
The intermediate DC is constant. With constant current, the current is delivered.
in almost constant form thanks to the inductor placed between the input of the
rectifier and the output bridge. With the cycle converters, each terminal of
output is connected to the correct input of each phase.

Characteristics

The frequency converters consist of the AC motor, the controller

and the operator interface. The motor is a three-phase induction one, the
The controller is a solid-state energy converter and the interface is the panel.
of control that allows humans to turn the dimmer on and off
frequency. The motor is made up of two types: the AC motor and the DC motor.

Speed variator

25
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 8 Speed Variator

Siemens micro master variator programming

1 Feed our variety with a source of 220 v.a.c and also

connect the motor with the terminals U1, V1, W1.

2 We adjust the power which we will do by pressing the key

Prog Data where the parameters will be displayed

With the up/down arrows ⬆⬇ we select parameter 0-

00 and we adjust it to the value of d5 to adjust the power to 750 w

3 To access the Current settings, we do it

Pressing the up/down keys⬆⬇ we move to the
parameter 0.02 then we give factory reset 9A

4 Next, to adjust the nominal tension of the motor, we press

the Prog Data key where we will select the parameter in the
screen With the up / down arrows ⬆⬇ We select the
parameter 1-02 and we set factory adjustment to 230V.

26
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

5 To enter the frequency configuration with a potentiometer

we do it by pressing the prog data button and using the arrows
up / down and we move to parameter 4.02 and
we configure to the frequency we want, in this case it would be 60
Hz.

Photographs of Micro Master 410 frequency inverter 220V

The figure shows the frequency scheme with the symbolism used by the
variable. See fig. 3.

Fig.9 Symbolism of speed variator for programming

MOTOR

The alternating current motor is a rotating electric machine capable of converting

the three-phase electric energy supplied, into mechanical energy. See fig.4. The
Three-phase electrical energy generates rotating magnetic fields in the winding of the
stator (the fixed part of the motor).

27
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig.10 Single-phase motor 2hp 220V.

Three-phase electric motors are manufactured in the highest powers, from a
fraction of horsepower (HP) to several thousand horsepower (HP),

they are built for practically all voltages and frequencies (Hz) and very
often, they are equipped to operate at two different nominal voltages.

They are used to operate machine tools, pumps, forklifts,

fans, cranes, aerial machinery, blowers, etc.

Operating principle

When the current passes through the windings of the three phases of the motor, in the
The stator generates a magnetic field that induces current in the bars.
rotor.

This current gives rise to a flow that, when reacting with the field flow,
The magnetic field of the stator generates a torque that will set the rotor in motion.
This movement is continuous, due to the continuous variations of the
three-phase alternating current. It should only be noted that the rotor cannot go to the
same speed as that of a rotating magnetic field.

This is possible because every moment receives impulses from the field, but when it ceases

push, the rotor lags, this phenomenon is called slip. After

from that moment a new push and a new slide will come and so
successively. In this way, it is understood that the rotor never manages to reach
the same speed of the rotating magnetic field. It is what is called
synchronous or asynchronous. The sliding can be greater as the increases.
engine load and logically the speed decreases.

The conductor tends to function as an electromagnet due to the current.

electricity that flows through it, thereby acquiring properties
magnetic, which cause, due to the interaction with the poles located in the
stator, the circular movement observed in the rotor of the motor.

Asynchronous or induction motor.

28
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Induction motors or asynchronous motors are those electric motors in which

the rotor never spins at the same frequency as the field does
magnetic of the stator. The greater the torque, the greater this difference is.
frequency.

Induction motors or asynchronous motors are propulsion machines.

most widely used electric motors, as they are simple, safe, and inexpensive. The motors
Asynchronous motors are classified according to the type of rotor, into cage rotor motors.

Squirrel (or motors with short-circuited rotor) and in wound rotor motors or
of rosant rings. An asynchronous motor consists of the following parts.

Fig.11 Single-phase asynchronous motor 2hp 220V.

Advantages

In various circumstances, it offers many advantages over engines.

combustion

At equal power, their size and weight are reduced.

They can be built in any size.
It has a pair of

29
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

high torque and, depending on the type of engine, practically constant.

Its performance is very high (typically around 75%, increasing
the same as the power of the machine increases).
This type of engines does not emit pollutants, although in the generation of
electric energy from most supply networks does emit
contaminants.

Guard motor

A motor guard is a thermal magnetic switch, specially designed for

the protection of electric motors. This special design provides the
device a trigger curve that makes it more robust against surges
Typical transient intensities of motor starts. The firing
magnetic is equivalent to that of other circuit breakers but the trip
thermal is produced with greater intensity and time. Its characteristic curve
it is called D or K.

The main characteristics of motor protectors, like those of others

thermal magnetic circuit breakers, are the breaking capacity, the
nominal intensity or gauge and the trip curve. Provides protection against
motor overloads and short circuits, as well as, in some cases, in the face of lack
of the phase.

Motor protector

30
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 12 Motor guard GV2ME14 - 60 Hz.

Measuring instruments

Devices used to measure electricity are referred to as measuring instruments.

that are used to measure electrical magnitudes and thus ensure the proper
operation of electrical installations and machines. Most are
handheld portable devices are used for assembly; there are other instruments
What are measuring converters and other measurement aid methods, the
analysis and review. The collection of data is becoming increasingly important in the
industrial, professional, and private sphere. Instruments are being demanded, above all,
practical measures that operate quickly and precisely and that offer
results during the measurement.

Digital DC Voltmeters

It is an instrument used to measure the potential difference or voltage between

two points of a closed electric circuit but at the same time open at the poles.

Red Lion Digital Voltmeter (APLVD-400)

They are the ones that provide a numerical indication of the tension, usually in a
LCD screen. They often have additional features such as memory, detection of
peak value, true effective value (RMS), automatic range selection and
other functions. See fig. 7

To measure the potential difference, the voltmeter must be placed

in parallel, that is, in derivation on the points between which it is being addressed

31
PRIVATE TECHNOLOGICAL HIGH SCHOOL *CIRO ALEGRIA*

take the measurement. Red Lion DC voltmeter, this meter obtains the
DC voltage generated and also works as a DC ammeter.

Fig. 13 LCD digital voltmeter.

It is a D.C. voltage meter. And it is a top-quality instrument designed

for demanding automotive applications. With the integrated performance capability
of multiple range according to the scale, this unit offers the latest in flexibility
application.

The attractive plastic cover not only enhances the appearance of any panel,
It can also be sealed on the front panel for use in areas and environments.
industrial and rough and dirty.

Digital DC Ammeters.

An ammeter is an instrument used to measure the current intensity.

that is circulating through an internal circuit.

Currently, ammeters use an analog-to-digital converter for the

measurement of the voltage drop across a resistor through which current flows
medir.

Red Lion digital ammeters (APLID-400)

To measure the intensity of the circulating current, the ammeter

it has to be connected in series, so that it is traversed by said current.

This leads to the ammeter having to possess an internal resistance as low as possible.

as small as possible, so that it does not produce a noticeable drop in voltage.

Specifications:

Operating voltage:

32
 CIRO ALEGRIA PRIVATE HIGHER TECHNOLOGICAL INSTITUTE

o4.5-30V DC

oNote: The maximum input voltage must not exceed 30 V, otherwise

there is a risk of burning

oWorking current: ≤20mA

oScreen: 0.28 'bicolor blue and red range

omedición: DC 0-100V 0-10A Resolución mínima (V): 0.1V

oUpdate frequency: ≥100ms / hours

oMeasure the accuracy: 1% (± 1 digit) Minimum resolution (A): 0.01A temperature

oOperating temperature: -15 to 70 °C Working pressure: 80-106 kPa.

otamaño: 47 × 28 × 16 mm / 1.85 * 1.10 * 0.63 '

oPeso Neto: 19 g

o Peso: 29 g

oThe package includes: 1 *

Ammeter of the voltmeter.

Tachometer

The digital tachometer allows measuring the frequency present at the output of
alternators in combustion engines, and display them as RPM on the output. See
fig.8. Its input circuits, specially designed for this function,
they also allow the detection of signals coming from various sources:
proximity sensors, keys and/or frequency outputs of special circuits
such as PLC, etc.

The preparation for panel assembly, and its special polycarbonate front for
this use, give them enough robustness for most applications of
mobile use.

Fig.14 Digital Tachometer of 4000 RPM.

33
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Technical Data Measurement range

Display input signal amplitude.

Nutrition Dimensions.

Input for night brightness reduction 400 to 4000 rpm.

Red, 4 digits of 14.2 mm. 0.5 to 12 Vac. 8 to 16 Vdc.

Diameter 90 mm.

Depth 30 mm. Yes, 12 Vdc.

Electrical conductors

An electrical cable, also called a power cable, is used to transmit

electric energy. Electric cables provide connection and allow for the
power stations, wired computer networks, televisions, and phones
functions. There are many types of electrical cables that differ in
configuration, size, and performance.

Measures of conductors

The diameters of cables and wires are categorized according to the system.
AWG (American Wire Gauge). The smaller the AWG number, the ...
mayor he diameter of a cable.
El diámetro de los alambres y cables está directamente relacionado con la
current that they can support, the larger the diameter they have, the more they will be able to

to drive more amperes (the current is measured in amperes A). If passed through
a current greater than it can handle, the cable could suffer

34
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

overheating and even cause a fire, in addition to generating a

waste of energy

Colors

Colors are used to facilitate the identification of wires or cables.

by the electrician or the person who does the electrical installations.
Generally, colors are used in the following way.

Insulations

As mentioned earlier, most wires or cables have a

isolation or a plastic coating to prevent them from short-circuiting
upon contact with any other wire or metallic object, that give a
electric shock or electrocute someone.
The names of the cables indicate the type of insulation they have and are
abbreviations that come from English, the most common cables for installations
Residential and office ones are THHN, THW, THHW, and THWN.

Caliber

The gauge defines the size of the cross-section of the conductor. The gauge
can be expressed in mm² or under American normalization in AWG
(American Wire Gauge). See fig.9. When expressed in AWG, the thickest is
4/0, followed in descending order by 3/0, 2/0, 1/0, 1, 2, 4, 6, 8, 10, 14, 16, and 18
what is the thinnest used in electrical installations. see fig.10. In this case,
the larger the number, the smaller the cross section of the
conductor. For conductors with an area greater than designated as 4/0, it is done
a designation based on its area in inches, called CM (circular
mil), following 250,000 CM or 250 KCM.

Electric conductor Fig. 15 Types of electrical conductors.

35
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig.16 Cable gauge and its determination.

Terminals

The terminals are attached to the ends of the electrical cables to facilitate
the connection of the cables to the terminals or pins of the equipment. See fig.11. The
The following must be considered in the selection of terminal wires: valuation
actual cable size (gauge) and the insulation diameter, conductor
compatibility of the materials, head size compatibility of the
insulation materials, application environment, and welding versus non-welding.

Fig.17 Coupling terminals.

36
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Belt transmission
Generalities

Belts are power transmission elements, made of flexible material,

that are coupled to pulleys that are attached to shafts in order to transmit
turning pairs. See fig.12.

Its flexible nature will allow its manufacturing to be carried out with a certain
mechanical uncertainty that can be assumed later in its assembly.

A simple belt transmission consists of a driving pulley and a pulley

driven and a belt, mounted with tension on some shafts and that transmits the
circumferential force due to friction.

Fig.18 Belt transmission.

37
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Trapezoidal belts

The trapezoidal belts or 'V' belts operate based on the contact that is
establish between the side flanks of the belt and the walls of the channel of the
pulley. See fig.13.

According to ISO standards, trapezoidal belts are divided into two main groups:
the section belts with the classic profiles Z, A, B, C, D, and E.

Fig. 19 V-type trapezoidal belts.

Where:

a: it is the width of the top face of the strap.

h: it is the height or thickness of the belt.

it is the so-called primitive width of the belt.

The trapezoidal or 'V' belts operate under optimal conditions when the
They operate at linear speeds within the range of 20 - 22 m/s. The V-belts.
they should not operate at speeds exceeding 30 m/s, given that the high
the centrifugal force generated would eventually pull the belt out of the groove of the
pulley.

38
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Pulleys
Pulleys are wheels that have the outer perimeter specially designed
to facilitate contact with ropes or straps. See fig. 14.

The correct placement of the belt in the channel or groove of the pulley
considerably influences the performance of the transmission and its lifespan
the current.

To achieve a good placement of the belt in the groove of the pulleys is

an essential condition is a perfect alignment between pulleys.

For this, it is necessary that the motor shafts are parallel and that the belt
I worked perpendicular to those axes.

Fig. 20 Types of pulleys.

39
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Electric circuit.

The connection diagram of 200V AC is shown. See fig. 15, for connection of the
electric motor and motor connections, for the operation of the bench.
alternator test.

Fig.21 220V electrical circuit for electric motor connections.

40
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Alternator
ELECTRICITY GENERATION IN THE VEHICLE.

Electric energy on board.

Motor vehicles need fuel for the energy supply to the engine.
start-up, injection and ignition system, control units of devices
electronics, safety and comfort electronics, lighting, etc., a source of
own energy that is efficient and reliable, and available at all times.

While in vehicles the battery plays the role of a storage unit

of energy when the engine is off, with it running the alternator is the
authenticates the vehicle's 'power plant'. Its mission is to supply
power to all devices on board. See Fig. 22.

Fig. 22 Principle of alternator.

41
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The power of the alternator, the capacity of the battery, and the consumption of the engine of

start-up and all other electrical consumers must be in

optimal conditions for the entire installation to operate safely
and without breakdowns.

After a typical walking cycle (e.g. urban commute in winter), the

the battery should still be sufficiently charged for it to be possible the
next start under the prevailing temperatures. They must always present
functional aptitude of the control units, sensors, and actuator elements of
the electronic systems (e.g. for fuel preparation, ignition,
the Motronic system, the electronic control, of the engine competition, the system
anti-lock, the anti-skid traction system.

In addition, the security system, the signaling equipment, and, in

the darkness or with fog, the lighting system.

The information and comfort systems must always be operational.

With the vehicle stopped, the electrical consumers must be able to function.
for a reasonable time without preventing the successive start.

Consumer powers

Electric consumers have different connection times. They

distinguishes between always-on consumers (on, injection of
combustible, etc.), prolonged connection (lighting, car radio, heater of the
vehicle, etc.) and brief connection (turn signals, brake light, etc.) depending
of the time of year.

Load balance calculation

In the calculation of the load balance, it is determined with the help of a program.
computer the battery charge status at the end of a typical operating cycle.

Generation of current using three-phase alternators.

The availability of inexpensive power diodes (since 1963

approximately) was the prerequisite for the serial introduction of

42
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

three-phase alternators by Bosch. For their greater utilization

electromagnetic conditioned by its execution and by the margin of revolutions
Essentially greater than with the direct current generator, the alternator
three-phase synchronous can deliver power even at idle speeds
of the combustion engine and meet the high power demand of the vehicle to
motor. Thanks to the ability to adjust the rotation speed of the alternator to
the motor through an appropriate reduction, the battery can
to maintain a good state of charge, even in winter and during driving
urban, characterized by frequent stops.

Influential magnitudes
Rotation speed

The performance of an alternator (energy generated per kg of mass) increases by

the speed of rotation; for this reason, care must be taken to ensure that the reduction ratio
between the engine's crankshaft and the alternator should be as high as possible. In the sector
tourism, the typical values are between 1:2 and 1:3; in the case of industrial vehicles
they reach up to 1:5.

Temperature

The losses in the alternator raise the temperature of the components. The
Fresh air supply to the alternator is an appropriate measure to reduce the
temperature of components and, with that, increase the lifespan of the alternator and its
performance cattle.

Vibrations

According to the assembly conditions and the vibration characteristics of the motor,
accelerations and vibrations of up to 500...800 m/s² occur. They must be avoided.
the critical resonances.

Other influences

Likewise, the alternator is exposed to the influence of water splashes.

the dirt, the oil and fuel fog, and the de-icing salt.

43
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Generation of electrical energy through generators of

current continues
The usual lead battery in the car led initially to the development of
DC generator. For a long time, this crude system for
essentially meet the demands raised.

Thus, until the mid-1970s, most motor vehicles were

equipped with direct current generators. Currently, however, they have
lost importance for the assembly in new vehicles and, therefore, has no
so much importance.

In direct current generators, it is advisable that it be the system of

induced from the rotor that spins and the magnetic system electrically
excited this is housed in the immobile casing. With this, it is possible, in a way
relatively simple. Mechanically rectify through an inverter of
current, the collector, the alternating current generated in the rotating system of
devised, to later transfer it to the electrical installation.

Requirements placed on generators in automobiles

The shape and structure of a car generator are determined by its purpose.
to supply electrical energy for the operation of electrical devices of
the vehicle installation and for its storage in the battery. The
Alternators initially generate alternating current.

Demand

Feeding, with direct current, of the connected consumers.

Power reservations for fast charging or battery recharging, even
being connected permanent consumers.
Maintain constant alternator tension throughout the range of
engine revolutions of the vehicle, independent of the load it is under
sometido el alternador.
Robust structure that withstands all external demands (e.g.
vibrations, high ambient temperature, temperature change, dirt
humidity, etc.)
Reduced weight
Favorable dimensions for mounting.
Long duration, low noise.
Good level of performance.

44
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

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

Power delivery even at idle.

Rectification of the three-phase current with power diodes in the circuit
three-phase bridge.
The diodes separate the alternator from the battery and the electrical system of
vehicle when the alternator voltage is lower than the voltage at the
battery voltage.
Greater electrical utilization (that is, with the same power,
Three-phase alternators are lighter than current generators.
continue).
Long lasting (car alternators have a useful life
comparable to that of the vehicle's engine; up to 150,000 km, which does not
they require maintenance during that time).
They are insensitive to external influences such as high temperatures.
humidity, dirt, and vibrations.
They can work in both directions of rotation without requiring measurements.
specials as long as the shape of the fan is suitable for the direction of
corresponding giro.

BASIC PRINCIPLES
Electrodynamic principle
The basis for generating tension is constituted by "induction".
electromagnetic, which takes place according to the following process. If a conductor
electric (wire or wire loop) moves cutting through the lines of force of
a magnetic field, an electric tension originates in said conductor
(induced). It is indifferent whether the magnetic field is fixed and the conductor is
move, or conversely be the conductor that is fixed and the magnetic field
the ones that move.

If the rotation of the conductive coil is uniform, the voltage curve is sinusoidal.
showing the maximum values after each half turn, if the circuit of
the circuit is closed, an 'alternating current' flows. Fig.23.

Fig.23 Induced single-phase alternating current.

45
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Principle of the three-phase alternator.

The three-phase current (see fig. 24) is generated by a rotational movement.

The advantage of alternating current is that it allows for better utilization of
alternator.

According to the principle, there are three equal and independent windings in the armature.
120" displaced from each other. It is common to designate the principles with U, V, W.
deadened and with x, z the endings. According to the principle of induction, when the rotor turns
Alternating sine voltages of equal magnitude are formed in the windings.
frequency. Due to the shift of 120 degrees between the windings, the voltages
alternates generated in them are out of phase with each other by 120°, and by
They are also out of sync with time.

Fig.25 Induced three-phase alternating current.

In this way, a cycle takes place that repeats constantly. The current
The resulting three-phase alternator produces a rotating magnetic field in a motor.
suitable.

Normally, a three-phase alternator would require six conductors to transmit the

energy generated if the windings were not connected (fig.26a), but using
The three circuits can reduce the number of conductors from six to three.

46
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The union of the circuits is made through a 'star connection' (fig.26b) or

a triangular connection” (fig. 26c).

In the case of 'star connection', the ends of the windings are connected to
a central neutral point. Without a central conductor, the sum of the three currents towards
The central neutral point is always equal to zero. Three-phase alternators.
with a stationary excitation field and the rotating armature winding, in which
induce the charging current.

Fig. 26 connection forms of the three windings.

Rectification of alternating current

The alternating current generated by the three-phase alternator is not suitable for the
battery nor for the power supply of the control units of the
electronic components. It needs to be rectified. Fig.27. A condition
important for rectification is to have suitable power diodes for
operate over a wide temperature range. The rectifier diodes
they present a sense of passage and a sense of blockage. The direction of the arrow
The connection symbol indicates the direction of flow. The rectifier diode allows that

47
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

negative semi-waves are suppressed and only positive semi-waves are allowed to pass through,
in such a way that a pulsating direct current is generated. In order to take advantage of
for the rectification all the semi-waves, including the suppressed negative ones, are
apply a double or full-wave rectification.

Fig.27 Rectification of alternating current to direct current.

Bridge circuit for rectifying three-phase current.

48
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The alternating tensions generated in the three windings of the three-phase alternator are
They rectify with six diodes in a three-phase current bridge circuit. Fig.28.
each phase has two power diodes connected, one on the positive side (to
terminal B+) and the other on the negative side (to terminal B-). The six diodes of
Power forms the three-phase rectifier bridge. The positive half-waves pass
through the positive side diodes and the negative half-waves through the diodes on the side
negative, thus rectified. The complete rectification with the bridge
the addition of the positive and negative envelopes of these semi-waves,
Thus, a slightly undulating voltage is obtained from the alternator. Fig.28.

Fig. 28 Circuit for the Conversion of Negative Waves to Positive.

The direct current that, under electric load, passes from the alternator to the
installation of the vehicle through the terminals B+ and B- is not "smooth", as
it would be ideal, if not slightly wavy. This slight wave is further reduced
but due to the effect of the battery, connected in parallel to the alternator, and, if applicable,

through capacitors installed in the vehicle's electrical system.

The excitation current that magnetizes the poles of the excitation field, is
derived from the stator winding. A full wave rectification connection
rectifies the excitation voltage. Fig.29.

49
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The three 'excitation diodes' of the D+ terminal and the three power diodes of the
negative side (terminal B-) forms the bridge circuit for the current of
excitement.

Fig. 29 Rectifier circuits.

50
PRIVATE TECHNICAL INSTITUTE *CIRO ALEGRIA*

Return current blockage

The rectifier diodes of the alternator not only serve to rectify the voltage of the
alternator and excitation, but they also prevent the battery from
download through the three-phase winding of the stator.

When the engine is stopped or runs at such a low rotational speed

(e.g. During the start-up), the alternator is not yet self-excited,
the battery current would circulate through the stator winding if they were not
diodes installed.

Regarding the battery voltage, the diodes are connected in the direction of
blocking, so that no discharge current from the battery can pass. The
current would only pass from the alternator to the battery.

Rectifier diodes
The power diodes of the positive and negative sides match completely.
regarding their function. They only differ by their structure intended for the
Rectification in the alternator is referred to as positive diodes and negative diodes.
The molded metal box of the diodes is made once as a cathode and
Fig. 29 b Current rectification circuits.
another as an anode. The metal box embedded in the positive plate of the diode
Positive is connected as a cathode to the positive terminal of the battery in this way, the

the diode conducts in the direction of the battery terminal B+. the metal casing
Embedded in the negative plate of the negative diode is connected as an anode to ground.
The terminals of the diodes are connected to the ends of the winding.
statoric. Fig.30. The positive and negative plates act simultaneously as
heat sinks for the cooling of diodes. Such as power diodes

51
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Zeners diodes (zener diodes) can also be used, which also limit
the voltage spikes that appear in the alternator in case of variations
load extremes.

Fig. 30 Excitation current rectification.

Three-phase alternator current circuit

The three-phase alternators have, in their standard version, three circuits of

corriente:

The pre-excitation circuit (external excitation by the current of the

battery

52
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The excitation circuit (self-excitation).

The alternator circuit or main circuit.
Pre-excitation circuit.

Pre-excitation circuit.

When connecting the power or contact switch (4), current flows from the
battery. As indicated in fig.31. Through the alternator control lamp (3), through the
deviated from excitement (1d), of the rotor and by the regulator (2), to mass. This
The battery current originates in the rotor, pre-exciting the alternator.

Fig. 31 Pre-excitation circuit.

Why pre-excitation?

53
PRIVATE TECHNOLOGICAL HIGH SCHOOL *CIRO ALEGRIA*

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

This tension is not enough to provoke a self-excitation intended for the

creation of the magnetic field.

Self-excitation can only occur when the alternator's voltage is

higher than the voltage drop across both diodes (2 x 0.7v = 1.4v).

This is achieved with the battery's pre-excitation current, conducted through

from the charge control lamp. The current generates a magnetic field in the
rotor, which induces a voltage in the stator proportional to the rotational speed.
When starting the engine, the 'starting speed' must be reached,
The induced voltage must be higher than the voltage drop across the diodes.
excitation circuit, so that self-excitation occurs. The 2regimen of
"Start-up" is superior to the idle regime (zero ampere regime).

Since the charge control lamp increases the resistance of the circuit
pre-excitation regarding the resistance of the excitation circuit. The power
established of the load control lamp thus influences the 'regime of
start

Alternator warning lamp

The alternator control lamp (3) located in the pre-excitation circuit
acts, when connecting the power switch or contact switch (4), as a
resistance that determines the magnitude of the excitation current. If it is a
correctly chosen the power of the lamp, the current generates a field
magnetic enough to trigger self-excitation. If the power
the lamp is too low, for example the electronic elements of
indication, it is necessary to connect a resistor in parallel, to ensure a
autoexcitación segura del alternador. Mientras está encendida la lámpara, la
the alternator voltage is lower than that of the battery. The lamp goes out at
when is the regime reached for the first time in which tension is generated

54
PRIVATE HIGHER TECHNICAL INSTITUTE *CIRO ALEGRIA*

maximum of the alternator and this delivers its power to the vehicle's electrical system.
The power ratings of the alternator control lamps are as follows:

2W for 12 V installations.

3W for 24 V installations.

Excitation circuit
The excitation current is tasked with creating a magnetic field during
all the operating time of the alternator, in the excitation winding of the
rotor, thus inducing the required voltage of the alternator in the windings of the
stator.

Because three-phase alternators are self-excited alternators, the

excitation current is derived from the current that passes through the winding of
three-phase current.

The excitation current fig.32 Passes through the excitation diodes (1a),
through the brushes and collector rings, via the excitation winding, towards
the DF terminal of the regulator (2), and from the D- terminal of the regulator, through
the power diodes (1c) return to the stator winding. During the
The operation of the alternator no longer requires any external power source.
for self-excitation.
Fig. 32 Excitation circuit.

55
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Alternator current circuit

The alternating current induced in the three phases of the alternator has to be
rectified by the bridge circuit equipped with power diodes, to be
transmitted to the battery and to the consumers. The current from the alternator passes
from the three windings, through the power diodes, to the battery and the
consumers of the vehicle's electrical system.

The alternator current is divided into battery charging current and into
power supply to consumers. Fig.33. This also suffers a
voltage variation.

In a rotor, e.g. with six pole pairs and a rotation angle of 30°,
tension regarding the neutral point of the star connection is positive at the
extreme V of the winding, negative in W and null in U.

The path of the resultant current from the above is represented in fig.34.

The current flows from the V end of the winding, through the diodes.
positive towards the alternator terminal B+, through the battery or the
consumers, towards mass (alternator terminal B-) and through the diodes
negatives towards the W end of the winding.

The phase tensions and phase currents constantly change from

magnitude and direction, while the direct current is for battery charging
and the feeding of electric consumers fundamentally retains its
sense of flow.

56
PRIVATE HIGH TECH INSTITUTE *CIRO ALEGRIA*

Fig. 33 Alternator circuit.

This effect is based on the fact that, for every possible position of the rotor,
all the diodes participate in the rectification.

In order for current to flow from the alternator to the battery, the voltage of
that one must be slightly higher than this one.

Fig.34 Winding voltages

57
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Voltage regulation
Why is voltage regulation necessary?

The mission of the voltage regulator is to keep the voltage constant.

alternator and with it the vehicle's electrical system, throughout the margin of
engine revolutions of this and regardless of the load and the
rotation speed.

The alternator tension largely depends on its rotation speed and the
load to which it is subjected. Despite these service conditions
continuously variables, it is necessary to ensure that the voltage is regulated to the value
pre-established. This limitation protects consumers against surges.
and prevents the battery from overloading.

When charging the battery, the electrochemical properties must also be considered.
from this. Normally, the level to which the regulator limits the voltage of the alternator
Yes, in cold, somewhat greater than in hot, to improve the battery charging, more
difficult under those conditions.

Principle of voltage regulation

The tension generated in the alternator is higher the greater its
speed of rotation and the excitation current.

The voltage regulator controls the value of the excitation current, and with that, the
magnitude of the magnetic field of the rotor, as a function of the magnitude generated in

the alternator. Fig.35

In this way, the voltage at the terminals of the alternator remains constant.
the B+ and B- terminals with variable speed and load, up to the maximum
current value.

58
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The electrical systems of cars with 12V battery voltage are

they regulate within the tolerance range of 14V and those of automobiles with 24V
Battery voltage is regulated to 28V. As long as the voltage generated by the
the alternator remains below the regulation, the voltage regulator
disconnect.

Fig. 35 Regulation of the excitation current.

If the voltage exceeds the prescribed upper theoretical value, within the framework of the
regulation tolerance, the regulator interrupts the excitation current.
excitation decreases, that is to say, the alternator tension goes down

If as a result of this the tension becomes lower than the theoretical value
inferior, the regulator reconnects the excitation current. The excitation
it increases and with it the alternator's voltage. When the voltage exceeds another
once the upper limit value is reached, the regulation cycle begins again. As
regulation cycles are on the order of milliseconds, the average value is regulated
of the alternator voltage in correspondence with the characteristic curve
pre-established.

59
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The continuous adaptation to the various rotational speeds is carried out

automatically. The relationship of the corresponding connection times and
Disconnection is determinant for the magnitude of the excitation current.
media. Under low regime, the connection time is relatively long and that of
short disconnection. The excitation current is interrupted only for a short time
and its average value is high. Conversely, at high rotational speeds the
the connection time is short and the disconnection time is long, and a current flows a
excitement is low

Influence of ambient temperature

The characteristic curve of the regulator, the battery voltage as a function of
temperature, is adapted to the chemical properties of the battery. At low
temperatures the tension of the alternator is somewhat higher to improve the load of the
battery in winter. It also takes into account the input voltages of the
electronic devices and the lifespan of bulbs, depending on the voltage. A
high temperatures result in lower alternator voltage, to avoid overload
from the battery in summer. The temperature compensation is achieved
through the appropriate selection of components. E.g. With Z diodes.

Structure of the alternator.

The relationships and theoretical principles discussed so far are found

materialized in the technical executions of the alternators. The different
Versions differ in certain details according to the field of application. The
interleaved pole alternator with monobloc structure was mounted
anteriormente en la mayoría de vehículos a motor, no obstante, cada vez se
more compact alternators are used in vehicles thanks to their reduced
size which takes up less space.

The essential differences between the structure of the compact alternator and that of the
Monobloc structure consists of the interior fans, the collector rings,
smaller, and the position of the rectifier, outside the bearing plate of the
collector rings. The fundamental structure is represented in fig. 36.

60
35,9$7( +,*+ 7(&+12/2*,&$/ ,167,787( &,52 $/(*5,$

%HQHILWV

7\SHV

&KDUDFWHULVWLFV

6SHHG
YDULDWRU
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Pulley

The drive pulley is also fixed to the rotor shaft. The rotors of the
three-phase alternators can rotate in both directions. The shape of the fan
should be established for a left or right turn in accordance with
the direction of rotation of the alternator.

Collector rings

Between the collector ring side cover and the drive side cover
The stator is fixed. The rotor shaft is housed in the two bearing halves.

Rectifier bridge

Rectifier with cooling plates. For the rectification of the current

Three-phase at least six power diodes are mounted under pressure on the plates of
refrigeration.

Brush holder with brushes

The excitation current flows through the brushes and the collector rings.
towards the rotating excitation winding.

Electronic regulator

The field electronic regulator attached to the alternator forms a single unit.
with the brush holder.

Alternator versions
Sizing criteria.

The following criteria are determining for the selection of alternators.

Vehicle type, service conditions.

Margin of revolutions of the combustion engine corresponding.
Battery voltage of the vehicle's electrical system.
Current demand from potential consumers.
Mounting conditions, dimensions.

The demands placed on an alternator differ considerably depending on the

type of use and the applicable criteria.

62
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Profitability criteria also vary with the fields of application. For

for this reason, there cannot be a universal alternator that meets all the
requirements. For the various application conditions and power margins
of corresponding types of vehicles and their propulsion engines, have been
developed various basic versions of alternators.

Data and construction sizes.

The required power of the alternator depends exclusively on the

consumers installed in the motor vehicle and not the size of the vehicle.

For the selection of an alternator, the determinants are mainly.

The voltage of the alternator (14V/28V),

The possible power delivery as a product of voltage and current, in
all the revolution margin,
Maximum current.

According to this data, the electrical sizing and the

required alternator size.

As a distinguishing mark of the construction sizes of alternators, there is

They use letters. The successive alphabetical order indicates the ascending size of
alternator.

An additional main feature is the alternator or rotor system (e.g.

interleaved pole alternator as a compact alternator or in version
monobloc, or with unipolar motor or guide rotor.

63
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Table N: 1.

Table of types of alternators.

Fig.37 Versions of alternators.

Compact alternators construction series B.
Application

The series B of compact alternators for passenger cars and industrial vehicles is
a refined version of the first generation compact alternator, with
longer lifespan, smaller dimensions, reduced weight and initial power
augmented. Fig. 38. The series consists of six construction sizes with 14V
of nominal voltage and three with a nominal voltage of 28V.

The narrow step allows for optimal adaptation to demand.

power and the available space in the engine compartment of the
modern automobiles.

Fig.38 Sectional view of a compact alternator.

64
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 39 Versions of compact alternators series B

Structure

The fundamental structure of a compact alternator of the construction series B.

fig. It is not different from that of a conventional compact alternator.

A new execution of the rectifier allows a greater airflow, therefore

better cooling. The three central sheets of the pack of sheets of
The stator is fixed and centered all around between the bearing caps.
In this way, it improves compared to the compact alternator of the
first generation, the resistance to vibrations and the transfer of heat from the
stator iron to the bearing caps.

The compact alternators of the construction series B are equipped with

multifunctional regulators.

65
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Fig. 40 Compact alternator of the B series.

SECURITY CONCEPTS

Work safety or occupational safety, along with occupational health and hygiene,
It aims for the implementation of measures and the development of necessary activities.
for the prevention of risks related to work. Safety in the
work is directly related to workers' rights and with
decent working conditions. More specifically, it addresses issues of
prevention of occupational risks through detection, evaluation and control of
the possible and real dangers within the work environment, as well as the risks
related to long-term work activity. The International Organization of
The work, an agency dependent on the UN, oversees the development of measures and
proposals for improving working conditions. An example of a measure
work safety is the use of helmets and protective equipment in the
civil construction.

What is risk.

Risk is the probability that a threat becomes a disaster.

vulnerability or threats, separately, do not pose a danger. But if
they come together, they become a risk, that is, the probability that an

66
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

disaster. However, risks can be reduced or managed. If we are

careful in our relationship with the environment, and if we are aware of
our weaknesses and vulnerabilities in the face of existing threats,
we can take measures to ensure that threats do not become
in disasters.

Danger

A danger is a thing or fact that has the possibility of causing physical harm or
a moral to an inert thing, or to a living organism. A real danger is when
the damage capacity is capable of causing effects immediately; and a
Potential danger is when it is latent, waiting for the conditions to arise.
to become effective.

Safety in industrial facilities during assembly.

To have technical knowledge

Learn and develop manual work skills
Know the inherent risks at each stage of the work.
Personal protective equipment.
Emergency protocols.
Use appropriate tools and in perfect condition, as this is essential.
It depends on personal safety and the preservation of work elements.
Safety in industrial facilities.
Carefully review the work to verify that it has been completed.
executed according to the plans and diagrams.
Check all connection points.
Never energize the circuit if you do not have the proper authorization.
Test functionality.
Check operation.
Personal protective equipment

Head protection.

67
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The elements of head protection basically reduce to the

safety helmets.
Safety helmets provide protection against impact cases and
penetration of objects falling on the head.
Safety helmets can also protect against impacts.
electric shocks and burns.
The safety helmet should not fall off the head during activities.
For work, a strap attached to the jaw can be used to avoid this.
It is necessary to inspect it periodically for cracks or
damage that can reduce the level of protection offered.

Safety helmet

Fig. 41 Safety helmet

Hand and arm protection.

The gloves provided to the workers will be selected from
according to the risks to which the user is exposed and to the
need for free movement of the fingers.
The gloves must be the appropriate size and kept in good condition.
conditions.
Gloves should not be worn when working with or near machinery.
movement or rotating.
The gloves that are broken, torn, or stained with
Chemical materials should not be used.
Types of gloves.

68
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Use of leather or canvas gloves.

To review welding or casting work where there is a risk of
burns with incandescent material it is recommended to use gloves
and heat-resistant sleeves.
For electrical work, insulating material gloves must be used.
To handle chemical substances, it is recommended to use gloves.
rubber or neoprene long ones.

Hand protection (gloves)

Fig.42 Hand protection gloves.

Protection of feet and legs.

Safety footwear must protect workers' feet against
humidity and hot substances, against rough surfaces, against footsteps
about sharp and pointed objects and against falling objects, it must likewise
protect against electrical risk.
Types of footwear.

69
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

For jobs where there is a risk of falling heavy objects such as

like metal ingots, plates, etc., must be equipped with leather shoes
with metal toe.
For electrical work, the footwear must be leather with no parts.
metallic, the sole must be made of an insulating material.
For work in wet environments, rubber boots with soles will be used.
non-slip.
For work with molten metals or hot liquids, the footwear is
will adjust to the foot and ankle to prevent the entry of such materials through the
slots.
To protect the legs against splashes of molten metals, one
will provide safety gaiters, which must be heat resistant.

Foot protection (safety shoes)

Fig.43 Safety shoes.

Work clothes
When selecting work clothing, the following must be taken into consideration
the risks to which the worker may be exposed and
will select those types that minimize risks.
Usage Restrictions.

70
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Work clothing should not pose a risk of getting caught or being

caught by the moving machine parts.
Sharp or pointed objects should not be carried in pockets, nor
explosive or flammable materials.
It is the staff's obligation to wear the work clothing provided by the
company during the workday.
Work clothes.

Fig. 44 Work clothing.

ENVIRONMENTAL CONCEPTS.
The 5 S.

71
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The 5S method, so named after the first letter of the name that
In Japanese, it designates each of its five stages; it is a management technique.
Japanese based on five simple principles.

It started at Toyota in the 1960s with the goal of achieving workplaces.

better organized, more orderly, and cleaner permanently for
achieve greater productivity and a better working environment.

Las5Shan have had a wide dissemination and there are numerous organizations of
of diverse nature that use it, such as: industrial companies, companies of
services, hospitals, educational centers or associations.

On the other hand, the methodology aims to:

Improve working conditions and staff morale. It is more pleasant and

it's safe to work in a clean and tidy place.
Reduce time and energy costs.
Reduce the risks of accidents or health issues.
Improve the quality of production.

Improve workplace safety.

The integration of the 5S satisfies multiple objectives. Each 'S' has a purpose.
particular
Japanese Spanish

Sort Classification and Discard

Set in order Organization
Seison Cleaning
Standardize Hygiene and visualization

Discipline Discipline and commitment

72
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

The 5 S.

Fig. 46it 5S
Contact with no one, but since canMethods.
eventually escape, it is a danger.
potential. If it escapes, it will become a real threat.

1st "S".

SEIRI: CLASSIFY.

Separate what is useful from what is not useful. Remove everything from the workspace.
the unnecessary elements for the workspace to be clear.

2nd "S".

SEITON: TO ORGANIZE.

A place for everything and everything in its place.

Order means more than appearance. Business order within the concept of
5S can be defined as the organization of the necessary elements of
in a way that makes them easy to use and access, each of which must be,
labeled so that they can be found, removed, and returned to their position easily

73
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

by the employees. The order is applied after classification and organization,

if it is classified and not organized, results will hardly be seen. They must be used
simple rules like, what is used the most should be closer, the heaviest
lightest at the bottom, etc.

3rd 'S'

SEISO: CLEAN.

Eliminate dirt and prevent getting dirty.

Clean the workspace and equipment, prevent dirt and clutter with a
superior cleaning thought.

4th "S".

SEIKETZU: CONSERVE.

Everything organized and clean is good for our physical and mental health.

Therefore, it is necessary to maintain high levels of disorganization, order, and cleanliness.

daily.

5th "S".

SHISUKE: SELF-DISCIPLINE.

Order, routine, and constant improvement.

Make it a habit to use and apply the established methods for the
compliance with the 4 "S" mentioned earlier.

OHSAS

It is a management system for occupational health and safety that contributes to the
improvement of conditions and factors that can affect the well-being of everyone
person who is in the physical environment of the company.

74
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Objective.

Companies that implement the OHSAS 18001 standard commit to eliminating

to minimize the risks for employees and other stakeholders that
pudieran estar expuestas a peligros asociados con sus actividades.

Certification mark.

OHSAS 18001 certification by a recognized entity, such as EQA (Entity

of Management Systems Certification), provides a visible demonstration
of the company's commitment to health and safety.

International standard ISO 14001

Today more than ever, environmental management is a crucial issue for the
success of any business. For many, the answer is a Management System
of the Environment (SGA), a framework in which to manage the impacts that are
they are produced in the environment, in addition to reducing costs, improving efficiency and

give companies a competitive advantage.

ISO 14001 is an internationally accepted standard that expresses how

establish an effective EMS. It is designed to achieve a balance between the
maintenance of profitability and reduction of impacts on the environment
environment, and with the support of organizations, it is possible to achieve both
objectives.

ISO 14001 is aimed at any organization, of any size or

sector that is seeking to improve environmental impacts and
comply with environmental legislation.

Principles
They should result in better environmental management;

They must be applicable to all nations;

They must promote a broad interest among the public and the users of the
standards;

75
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

They must be cost-effective, non-prescriptive, and flexible in order to cover

different needs of organizations of any size in
any part of the world; as part of their flexibility, they must serve the
purposes of both internal and external verification;

They must be based on scientific knowledge;

They must be practical, useful, and usable.

Definitions

environment: the setting in which an organization operates, including the

air, water, soil, natural resources, flora, fauna, beings
humans and their interrelations.
Environmental impact: any change in the environment, whether...
adverse or beneficial, as a total or partial result of the aspects
environmental aspects of an organization.

preventive action: action to eliminate the cause of a non-conformity

power.
prevention of pollution: use of processes, practices,
techniques, materials, products, services or energy to avoid, reduce or
control (separately or in combination) the generation, emission or

discharge of any type of contaminant or waste, in order to reduce

adverse environmental impacts.
environmental aspect: element of the activities, products, or services of
an organization that can interact with the environment.

Environmental risks

Electrical conductor: copper.

Professional exposure to Copper can occur. In the work environment,

Contact with copper can lead to catching the flu known as metal fever.
This fever will pass after two days and is caused by hypersensitivity.

Long-term exposure to copper can irritate the nose, mouth, and eyes and
causar dolor de cabeza, de estómago, mareos, vómitos y diarreas. Una toma

76
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

large amounts of copper can cause damage to the liver and kidneys and even death. If
Copper is carcinogenic has not been determined yet. There are scientific articles.
that indicate a union between long-term exposures to high levels
copper concentrations and a decrease in intelligence in adolescents.

Electrical conductor waste 'copper'

Fig.47 Electrical conductor waste.

Workshop plans, schemes/diagrams.

Fig.48 Work area distribution plan.

77
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

30.00
13.50 .101.40 .15 4.00 .15 10.55 . 15

LAVADERO
MESA
MESA
OFI CI NA

AREA DE TRA BAJO

ALMACEN BANDEJA
COMPRESORA

.15 4.00 .15 1.50 1.50 7.55

TALER AREA

29.85 . 15
30.00

Nombre Fecha MEC ATRONIC A AUTOMOTIVE

Dibujado C. V.T.
ZONALLAM BAYEQ UE
Revisado
Escala Tema N° de Plano

S/E
WORKSHOP PLAN P-01
mts

Location plans

Fig.49 Photograph of workshop facade, entrance door.

78
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

ASPECTS

Fig. 50 Workshop location sketch.

ADMINISTRATIVES

MATERIALS LIST.

79
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Los materiales son adquiridos de manera comercial de acuerdo a las necesidades

of this project.

DESCRIPTION QUANTITY

Thermomagnetic switch 01 unit

250AMP Tripolar.

Cablero12 AWG indeco 08 meters

08 meters
Automotive cable n 14

Eye terminals gauge no. 16 4 units.

Automotive cable gauge 1.0 2 meters.

15 units.
Bolts ¼ x 1”
Bolts 10.5 01 unit.
4 units.
35 mm eye terminals.
Speed variator 220 V 01 unit.
3M insulating tape 01 unit.

01 unit.
Motor protector
LCD voltmeter and ammeter 01 unidad.
Tachometer 01 unit.

It had a square of iron 01.1/2 rods x 7 meters.

Tuboflex 1 inch 01metro.

Pilot light. 01 unit.

Quotation for materials to be used.

PRODUCT Cantidad Precio por Precio total

unity.
Motor guard 1 S/ 65.00. s/ 65.00

80
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

2HP electric motor 1 S/ 850.00. S/ 850.00.

2HP variable frequency drive 1 S/895.80. S/895.80
22OV.
LCD screen (voltmeter) 1 $25.00. S/80.00.
amperimeter.
RPM indicator. Screen 1 $/65.00 $200.00.
LCD.
Indeco 12 AWG cable 8mt s/1.00 s/8.00
Cable n 1.0 2mt $15.00 $30.00
Automotive cable number 14. 8 s/1.00 s/8.00
Bolts ¼ x 1” 15 s/0.30 S/4.50
Bolts 10.5 1 $3.50 S/3.50
Eye terminals number 16 4 s/1.50 s/60.00
1" square iron tube. 11/2barillas s/ 25.50 s/40.00
6mm plate 80x80. 1 s/100.00 s/100.00
A36 platinum plate 1 s/10.00 s/10.00
30x30.
Metal sheets of 2 s/80.00 s/160.00
aluminum 240 x 120.
Welding electrodes 12 s/0.50 s/6.00
Battery terminals 2Pac s/5.00 s/10.00

s/
2.530.80

Due to the high cost of the equipment, if one wishes to acquire it commercially, one must
recommend developing the proposed implementation proposal.

SCHEDULE OF ACTIVITIES

August September October November December

81
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

WEEKS 1 2 3 4 1 2 3 4 1 2 3 4 1 2

Name of the
project
Data from
project
Objectives of
project
Description of
innovation
or improve or
change
proposed
Plans
schemes and
diagrams
Theoretical framework

of the project.
Cost,
budget and
profitability
of the project
Schedule
of activities
Conclusions
finals
Linkographies
Attachments

CONCLUSIONS AND RECOMMENDATIONS

82
PRIVATE HIGH TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

Conclusiones:
The programming of the speed variator will be carried out with the help of
qualified personnel to carry out the process.
Production can be increased because having the equipment
there will be no need to go elsewhere to test the component. For
so much time will be taken advantage of that was previously used to leave the workshop,

carrying out other activities for the benefit of the company.

Thanks to this testing team, the diagnosis of the component will be more
efficiently, reducing the delivery time of the work. Having the
security of perfect functioning and work performance. And
satisfy the needs of the customer.
Recommendations:
Do not operate the equipment with wet hands.
Secure the component to be tested properly.
Plug in the power supply, with the respective care.
Follow the proper equipment handling order to avoid damaging it.
It is recommended to conduct a brief inspection of the cables before
to perform any work.
The cables must be perfectly insulated to avoid any
accident.

Bibliography.

MANUAL.

Automotive electricity and electronics (alternators).

Edition 2000
PRIVATE HIGHER TECHNOLOGICAL INSTITUTE *CIRO ALEGRIA*

MANUAL:

SPECIALIZED SCHOOL OF ENGINEERING ITCA- FEDAPE.

DIRECTORATE OF RESEARCH AND SOCIAL PROJECTION.

DESIGN AND CONSTRUCTION OF TESTER

ALTERNATORS AND STARTING MOTORS FOR
VEHICLES

MANUAL:

DESIGN AND CONSTRUCTION OF A TEST BENCH FOR

DC GENERATORS OF FIGHTER AIRCRAFT N22 WING.

AUTHOR:

EDINSON IVAN DOMINGUEZ CHUIZA.

84