How to make the alternator run more efficiently?

How to make the alternator more efficient, with higher output power and less heat? It is especially important that the output is as large as the generator speed is relatively low.

How to make the alternator run more efficiently? First find out the reasons for the inefficiency; secondly find a solution. Here's how to make the alternator run more efficiently:

First, the first step is to find out the reasons for the low efficiency.

1. Just look at the claw-pole rotor and you will know that it is not worth the trouble. A shaft, a pair of claw-shaped magnetic poles, a coil set and a collector ring are enough to form the entire rotor. The problem is that this design has magnetic flux leakage. Not all flux is used to "cut" the coil for maximum current output, some of which leak out and do nothing.

2. One solution is to use the Hybrid rotor. The general rotor claws are empty, and the Hybrid rotor has a permanent magnet between the claw poles. The magnetic flux exits the magnet and enters the melon pole, and returns to the magnet through the rotor mandrel and the claw pole on the other side of the magnet. After the permanent magnet is filled with the claw pole gap, the magnetic flux generated by the rotor winding will not leak away. This forces more flux from the rotor into the stator windings, thereby increasing the output efficiency of the alternator.

3. This scheme can increase the original efficiency by 20% on the basis of 50%. In this way, when the total efficiency of the alternator is 60%, only 5000W of power is needed, and about 4474W can produce the same output as the original one. The added benefit is that the amount of heat that must be dissipated is less than 1000W.

Second, the second step of generator improvement must be to install a water jacket around the generator and connect it to the engine cooling system. This is very beneficial.

1. Since the water jacket is actually used for cooling, it is not necessary to place the alternator in the flow of cold air entering the engine compartment. Moreover, the water jacket reduces the speed of heating or cooling of the generator, which is beneficial to improving the durability of the generator. This is because sharp temperature changes are detrimental to materials with different rates of expansion and contraction, and the use of water jackets eliminates this concern.

2, the water jacket naturally has other advantages. For example, Visteon claims in its data that its alternator can transfer nearly 1250 W of heat loss to the cooling system, and this heat is eventually consumed at the vehicle's defrosters and heaters to help clean the windshield and Heat the passenger compartment. Therefore, the coolant and the engine can warm up and warm faster, and the catalytic converter can ignite more quickly, which greatly reduces the exhaust emissions during cold start.

Third, the use of new AC generators developed by Ecoair. Efficient and economical. A 20% increase in efficiency has such a large effect and higher efficiency. This is the key technology for the new alternator developed by Ecoair.

(1) Advantages of the new alternator:

1. The generator designed by Ecoair is put into production, mainly used in vehicles such as ambulances, because in the ambulance, the work of flashlights, medical equipment for vehicles requires a lot of power. The basic concept of Ecoair can be applied to all vehicles, including dual-powered vehicles, and this generator is also theoretically applicable to the 42V electronic system that will be available in 2003.

2, the attractiveness of the alternator is also its fuel economy, especially when idle or low speed operation. Bosch has learned from an empirical approach that for every 5% increase in alternator efficiency, fuel economy will increase by about 1%. The comparative test conducted by DaimlerChrysler shows that the eco-performance of the fuel is improved when the ACair's alternator and the transmission's gearbox work together in the idle condition, when the input is constant and the output power is increased by 13.4%. %.

3. Although the rotor adopts a two-part structure and its internal design is intricate, it also brings some unexpected benefits. For starter motors, the duplex design gives it 80% efficiency. This means that a power of 200 amps (3000 watts) can be achieved with only 3750W or slightly less than 3730W. At the same time, due to the small power and heat loss of the driving generator, the output size of the generator can be made smaller, the weight can be lighter, and the like at a certain output power.

(2) The structure and working principle of the generator of Ecoair:

1. In one of the designs, the rotor is actually composed of two separate sections mounted side by side on the rotor mandrel, one of which is fitted with a permanent magnet to form 12 poles, and the magnet and the surrounding metal itself have a magnetic force. It does not depend on the rotor current; the other half of the rotor assembly is a winding coil, and there is a certain assembly relationship between the coil and the pole piece.

2. The Ecoair alternator has three independent modes of operation. At low speeds, the permanent magnet portion of the rotor causes current in the stator. During start-up operation, both the permanent magnet and the winding coil produce maximum flux, which causes the generator to produce maximum output. Therefore, the electromagnet always brings some problems, that is, how do you cut off the current or reduce the magnetic flux to reduce the power output when necessary? To solve this problem, the third mode is used to operate the Ecoair alternator. This mode is called "compensation" (buck),

3. The working principle of the Ecoair alternator:

When the output current exceeds the requirements of the electronic system, the current through the rotor coil portion is first reduced to zero. If the output current is still too large, the direction of the rotor coil current will be converted. When the current is reversed, the winding coils are magnetically opposite to the permanent magnets. Thus, by controlling the polarity and the amount of current in the coil portion of the rotor, it is possible to reduce the output of the alternator to zero - the same technique is also applied to a fail-safe safety circuit.

The importance of alternators and charging systems in any design issue cannot be underestimated. If it is not because the available power is limited, fuel-efficient components such as electric-powered pumps, engine oil pumps, power steering devices, and brakes will now appear. However, perhaps only a high-efficiency, high-power, 42V AC generator will be a solid bridge to the other side.