Three Phase Generator with Hybrid Controller Trainer
(AT - 095)
  • How to diagnose a fault within a car’s charging system
  • Relation between Battery Voltage and Battery Depth of Discharge (DOD).
  • Battery State of Charge Capacity (SOCC).
  • Battery State of Charge Energy (SOCE).
  • How does generated three-phase alternator output voltage change with fixed field current and variable engine speed.
  • How does generated three-phase alternator output voltage change with variable field current and fixed engine speed
  • How alternator three-phase voltage is converted to DC voltage
  • Effect of loading on car alternator
  • Examine how Hybrid Controller and Multifunction Controller respond to engine speed variation
  • Examine the response of Hybrid and Multifunction Controller during alternator loading conditions
    • How to troubleshoot following faults
    • Battery disconnection.
    • Alternator disconnection
    • Regulator disconnection.
  • Power Module
    • 220 VAC output terminal
  • Rectifier Module
    • 400uF to smooth rectifier output
    • Five pairs of output terminals (T1+,T1- to T5+, T5-)
  • Regulator Module
    • Operating voltage: 220VAC
    • Output terminals: regulated DC output 5~14 VDC
  • Fuse Box Module
    • Fuse ratings: 10A and 15A
  • Load modules
    • Load voltage: 12 VDC
    • Tungsten bulb rated as 12V 55 W, along with a power resistor rated as 2.5ohm and 55 W.
  • Alternator Control Module
    • Operating voltage: 220VAC
    • Speed indicator
    • Ten-pin socket
  • Alternator Voltage/Current Indicator Module
    • Operating voltage: 220V
    • DC voltage indicator: up to 200 VDC.
    • Current indicator: up to 100 A.
  • Load Voltage/Current Indicator Module
    • Operating voltage: 220V
    • Current1 & Current 2”: measures direct current up to 10A DC
    • Voltage 1 & Voltage 2”: measures direct voltage up to 500VDC
  • Power Socket Module
    • Operating voltage: 220V
    • Socket output voltage: 220 VAC
    • Socket output current: 10A AC
  • Car Battery Module
    • Operating voltage: 220V AC
    • Two pairs of output terminals:
  • High power 16 mm cable- “+ve” (red cable) and -ve black cable”, carries up to 60 A.
  • Low power 4mm “+ve” (red terminal) and -ve (black terminal), carries up to 8A.
    • Battery voltage: 12 VDC
    • Battery capacity: 63 Ah.
    • DC circuit breaker: 220 VDC.
  • Remote Access Module
    • Operating voltage: 220V AC
    • Output voltage signal (Hybrid to Load 1): 12 VDC.
    • Output voltage signal (Battery fault): 24 VDC.
  • Three Phase Generator with Hybrid Controller Trainer (AT - 095)
  • Hard copy user manual

The trainer is a modular educational system that consists of two units connected to each other by cables to allow trainees to understand in a very detailed way the internal electrical connections of automotive charging system and how to troubleshoot it safely. The trainer contains main components of automotive charging system as separated experimental modules with safety terminals to perform a wide range of experiments. The trainer is also supplied with a software for test and measurement purpose. Trainees enter experiments parameters to the software which automatically processes this data for tests and measurements.

                                     
  • The trainer consists of two units, an alternator test stand and a modular frame with interchangeable experimental modules that contains the automotive internal components with test terminals.
  • The alternator test stand consists of a real alternator that is used for automotive charging system, electric motor to simulate the car engine, a pully to tight the belt that transfer power from the electric motor to the alternator and alternator test stand panel.
  • The electric motor is connected to an AC driver (inverter) to provide various speeds.
  • Alternator test stand panel consists of ON /OFF switch of alternator test stand, emergency switch, Temp/Phase Error indicator lamp, a circuit breaker and a plug to connect the test stand to power panel at the modular frame.
  • The test stand also includes a schematic diagram of alternator mechanical system. The test stand is supplied with a transparent protective shield against rotating parts.
  • Modular frame is a sturdy chassis that allows trainees to easily change and install modules in order to rearrange them according to the desired experiment.
  • The experimental modules represent an exploded alternator, as each module contains one of alternator internal component.
  • Modular frame also contains main modules; regulator module, alternator control module, rectifier module, battery module and auxiliary modules; fuse box, alternator voltage/current indicator, Load Voltage/Current Indicator, Power Socket, Remote Access in addition to four load modules.
  • Power module includes a Circuit breaker, ON/Off switch of the trainer, Emergency switch, 220 VAC output terminal, Neutral and Earthing output terminals, Data connections section, 16-pin plug to connect the power module to alternator test stand, 2 USB sockets and 10-pin plug to connect to connect the power module to alternator test stand.
  • Power module also includes alternator›s internal wiring and schematic diagram.
  • The battery module contains a real battery whose terminals are connected internally to the module terminals.
  • This module also a circuit breaker for battery safety and an operation LED.
  • Alternator voltage/current indicator module includes meters to display output current and voltage of alternator to indicate how much voltage and ampere are supplied from the rectifier connected to the alternator rotor to the battery.
  • Trainer allows trainees to understand how electricity is provided to a car by studying the dynamo which is three phase asynchronous wound rotor generator that supply the battery with DC current through a rectifier.
  • Alternator control module displays the engine speed to indicate any problem in battery charging, as the more electrical loads are, the more engine speed is, which can be indicated by the engine speed digital display.
  • Alternator control module also includes ignition switch of alternator to allow trainees to understand difference between ON position and START position of car ignition switch, as ON position allows driver to operate car electrical systems like AC or radio without starting the car engine, while START position operates the starter to start the engine allowing it to perform the first combustion cycle, so the engine acts as the prime mover of the dynamo that charge the battery with 12 DCV.
  • The regulator module works as feedback from the battery to supply it with exactly 12V by keeping flux of alternator’s rotor constant in order to keep the rotor voltage constant at 12V.
  • Regulator regulates the input voltage of the battery. If voltage is lower than 12V, regulator supplies battery with voltage higher than 12 V, while if the battery voltage is 12V, the regulator supplies the alternator’s rotor instead of the battery in order to allow the alternator to supply car electrical systems.
  • Regulator module also shows two types of regulators, 1-phase regulator for star connected dynamo, 2-phase regulator for delta connected dynamo.
  • Also, there is two types of regulators, transistor-based regulator (cut out) with only DC feedback from the battery and microcontroller -based regulator (ASIC) with DC feedback from the battery or ACM feedback from the dynamo stator, in case the DC terminals of regulator is disconnected for any external reason.
  • Each module has its component name and symbol printed with for electrical connections.
  • The trainer is supplied with a software with various functions.
  • Software can record and display all dynamo characteristics like generated voltage, power, field current, armature current (charging current supplied from rotor to battery), engine speed and torque.
  • Software also enables to remotely connect and disconnect modules into the system.
  • Software can also simulate various faults
    • Battery disconnection.
    • Alternator disconnection
    • Regulator disconnection.
  • Battery module, regulator module and four loads’ modules have Enable/Disenable switch to allow trainees to perform experiments remotely outside laboratory in case the switch is set to Enable.
  • Remote access module is supplied with a USB socket and connection terminals for the external modules to be used to operate the trainer remotely outside laboratory to support remote learning by connecting all modules electrically to this module, so the whole trainer can be operated and controlled remotely via software.