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Alternator

2008-10-26T22:25:00.000-07:00

What Is The Alternator Of A Car?

An automotive charging system is made up of three major components: the battery, the voltage regulator and an alternator. The alternator works with the battery to generate power for the electrical components of a vehicle, like the interior and exterior lights, and the instrument panel. An alternator gets its name from the term alternating current (AC).

Alternators are typically found near the front of the engine and are driven by the crankshaft, which converts the pistons' up-and-down movement into circular movement. (To learn more about the basic parts of car engines, read How Car Engines Work.) Some early model vehicles used a separate drive belt from the crankshaft pulley to the alternator pulley, but most cars today have a serpentine belt, or one belt that drives all components that rely on crankshaft power. Most alternators are mounted using brackets that bolt to a specific point on the engine. One of the brackets is usually a fixed point, while the other is adjustable to tighten the drive belt.

You can spot the alternator (with the tag hanging off it) in the foreground of this shot of a stock car engine. You can also see the serpentine belt looped around it.

Alternator Components

For the most part, alternators are relatively small and lightweight. Roughly the size of a coconut, the alternators found in most passenger cars and light trucks are constructed using an aluminum outer housing, as the lightweight metal does not magnetize. This is important since aluminum dissipates the tremendous heat generated by producing the electrical power and since the rotor assembly produces a magnetic field.

If you closely inspect an alternator, you'll find it has vents on both the front and back side. Again, this aids in heat dissipation. A drive pulley is attached to the rotor shaft on the front of the alternator. When the engine is running, the crankshaft turns the drive belt, which in turn spins the pulley on the rotor shaft. In essence, the alternator transfers the mechanical energy from the engine into electrical power for the car's accessories.

On the back side of the alternator you'll find several terminals (or connecting points in an electrical circuit). Let's take a look at those:

* S terminal - Senses battery voltage
* IG terminal - Ignition switch that turns the voltage regulator on
* L terminal - Closes the circuit to the warning lamp
* B terminal - Main alternator output terminal (connected to the battery)
* F terminal - Full-field bypass for regulator

Cooling is essential to an alternator's efficiency. It's easy to spot an older unit by the external fan blades found on the rotor shaft behind the pulley. Modern alternators have cooling fans inside the aluminum housing. These fans operate the same way, using mechanical power from the spinning rotor shaft.

This diagram shows the diodes, rotor assembly and stator, all of which you wouldn't normally see without opening the alternator.

As we start to disassemble the alternator, we find the diode rectifier (or rectifier bridge), the voltage regulator, slip rings and brushes. The regulator distributes the power the alternator creates, and it controls the output of power to the battery. The rectifier bridge converts the power, as we'll learn in the next section, while the brushes and slip rings help conduct current to the rotor field winding, or wire field. Now let's crack the coconut open.

This is what you might see if you were to open your alternator.

Opening the alternator reveals a large cylinder with triangular finger poles around the circumference. This is the rotor. A basic alternator is made up of a series of alternating finger pole pieces placed around coil wires called field windings that wrap around an iron core on the rotor shaft. Since we know the pulley attaches to the shaft, we can now visualize how the rotor spins inside the stator. The rotor assembly fits inside the stator with enough room or tolerance between the two, so the rotor can spin at high speeds without striking the stator wall. On each end of the shaft sits a brush and a slip ring.

As we touched on briefly, alternators generate power through magnetism. The triangular finger poles fixed around the circumference of the rotor are staggered, so the north and south poles alternate as they surround the wire rotor field windings. This alternating pattern creates the magnetic field that in turn induces voltage into the stator. Think of the stator as the catcher's glove as it harnesses all the power created by the spinning rotor.

Alternator Replacement

Sometimes alternators are easily accessible and simple to replace for the amateur mechanic. With a modest amount of automotive experience and the proper tools, replacing an alternator in your garage can be done. But more and more cars don't have room under the hood, and the alternators can be difficult to reach without first removing several other components. In this case, it's best to take your car to an experienced technician who can do the job quickly.

If you happen to own an alternator that has a repair kit available for sale, you can really save some money. Alternator repair kits run between $12 and $30, depending on which components you need to fix. Again, you need the proper tools and a little know-how, but if you're able to find the right kit and know what you're doing, you can rebuild an alternator for a fraction of the cost of even a remanufactured unit.

One thing is certain: A bad alternator will ruin a good battery if you don't address it quickly. Batteries can only be recharged so many times before they'll lose their ability to hold a charge. For the most part, if the battery isn't relatively old, it should survive. But an older battery that is constantly drained and charged, drained and charged will have a shorter life span than a battery operated under normal conditions. The average life span of a battery is usually around 48 months.

High-output alternators have become popular with custom car shops and in high-performance cars. They produce higher voltage at idle and make more power for vehicles that draw an excessive amount of electricity. For example, custom cars with lavish audio and video systems draw more electricity than the stock alternators can handle. As a result, companies such as HO Alternators make alternators for several makes and models. Some custom shops are even installing dual-alternator systems to handle the additional electrical loads seen in custom vehicles.

The Life And Death Of An Alternator

One of the most common failures is bearing failure. The needle bearings that allow the rotor to spin freely inside the stator can break down from dirt and heat. When the bearings fail, the rotor will not spin efficiently and can eventually seize. Usually an alternator with bearings failure makes a loud grinding noise. If you suspect this problem, it's only a matter of time before the alternator gives up. Older vehicles with generators tend to require much more maintenance than newer models, but there's no hard and fast rule for how long an alternator will last. It varies from manufacturer to manufacturer.

You can take several easy steps to diagnose whether your alternator is on the fritz. First, most cars today have a dashboard light that glows when the ignition is switched on. This light usually is represented with a symbol of a battery. Have you ever heard a buzzing noise when the key is on, but the car isn't running? That's the voltage from the battery running through the charging system. If this bulb is burned out, chances are the alternator won't work. The car may start, but as we learned, it's just a matter of time before the battery drains and the electrical system fails.

As a rule, a three-phase alternator can operate with only one of the stator windings operational, although it's only one-third as efficient. To test whether your car had an issue with one of its stator windings, you'd need to use a voltmeter to check the voltage. (You can buy a basic voltmeter at an electronics store.) This is called a load test. Since the battery produces DC power, set the voltmeter to DC rather than AC. Connect the red lead (or wire) to the positive terminal and the black to the negative. With no accessories on, start the car and raise the RPM to around 1,000. The voltage should register around 14 volts. Anything less than 12 may indicate a problem. Next, turn on the headlights, air conditioner, radio and anything else that draws electrical power. Rev the engine and check the voltmeter. Again, the voltage should register around 14 volts. If you have a failing alternator, the voltage will be well below 14 volts. If so, it's time to replace the alternator.

Before you decide you need to yank the alternator and replace it, make sure you check the serpentine belt. If the belt is worn or loose, the alternator won't function properly. A bad belt is easy to replace and won't set you back much, usually less than $20. But if you have to replace the alternator, you have options.

Air Filter

2008-10-26T16:03:00.000-07:00

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Functions Of Air Filter

An air filter is a device which removes solid particulates such as dust, pollen, mold, and bacteria from air. Air filters are used in applications where air quality is important, notably in building ventilation systems and in engines, such as internal combustion engines, gas compressors, diving air compressors, gas turbines and others.

Some buildings, as well as aircraft and other man-made environments (e.g., satellites and space shuttles) use foam, pleated paper, or spun fiberglass filter elements. Another method uses fibers or elements with a static electric charge, which attract dust particles. The air intakes of internal combustion engines and compressors tend to use either paper, foam, or cotton filters. Oil bath filters have fallen out of favor. The technology of air intake filters of gas turbines has improved significantly in recent years, due to improvements in the aerodynamics and fluid-dynamics of the air-compressor part of the Gas Turbines.

Used auto engine air filter, clean side

Used auto engine air filter, dirty side

Auto engine air filter clogged with dust and grime

Climate Control Air Filter

There are four main types of mechanical air filter media: paper, foam, synthetics, and cotton.

Air filters are found in most all forced-air heating, ventilation, and air conditioning systems. The efficacy of the air filters in such systems significantly affects the Indoor Air Quality. Building industry recommended practices and government guidelines contain minimum recommended efficiency ratings for air filters. For example, the US Department of Energy recommends air filters with a Minimum Efficiency Reporting Value (MERV) of 13 as determined by the ASHRAE 5.2.2-1999 test protocol and LEED advises builders similarly. And ASHRAE recommends MERV 6 or higher air filters to control the amounts of pollen, mold, and dust that reach the wet evaporator coils in air conditioning systems. Wet coils contaminated with high levels of pollen and dust can allow mold colonies to grow.

Since efficacy drops beyond a certain dirt-loading level, filters must be serviced regularly. There are a variety of different types of HVAC filters available. Many are inexpensive and not very efficient. Many in-duct filters for home forced air heating and air conditioning systems are made from loosely-spun fiberglass. These filters are inexpensive, disposable, and come in various densities and sizes. Less-dense filters allow for higher airflow, but do not remove as much dust. Higher density filters remove more particles, but are more resistrictive of airflow. They also become more quickly loaded with dirt.

Polyester and or glass fibres are commonly used to make air filters. Both materials have high temperature ratings of at least 120°C (250°F), and are widely used in commercial, industrial and residential applications. Polyester and glass fibres can be blended with cotton or other fibres to produce a wide range of performance characteristics. In some cases Polypropylene, which has a lower temperature tolerance, is used to enhance chemical resistance. Tiny synthetic fibres known as microfibres are used in many types of HEPA (High Efficiency Particulate Air) filters.

Internal Combustion Of Air Filter

The combustion air filter prevents abrasive particulate matter from entering the engine's cylinders, where it would cause mechanical wear and oil contamination.

Most fuel injected vehicles use a pleated paper filter element in the form of a flat panel. This filter is usually placed inside a plastic box connected to the throttle body with an intake tube.

Older vehicles that use carburetors or throttle body fuel injection typically use a cylindrical air filter, usually a few inches high and between 6 and 16 inches in diameter. This is positioned above the carburetor or throttle body, usually in a metal or plastic container which may incorporate ducting to provide cool and or warm inlet air, and secured with a metal or plastic lid.

Paper

Pleated paper filter elements are the nearly exclusive choice for automobile engine air cleaners, because they are efficient, easy to service, and cost-effective. The "paper" term is somewhat misleading, as the filter media are considerably different from papers used for writing or packaging, etc. There is a persistent belief amongst tuners, fomented by advertising for aftermarket non-paper replacement filters, that paper filters flow poorly and thus restrict engine performance. In fact, as long as a pleated-paper filter is sized appropriately for the airflow volumes encountered in a particular application, such filters present only trivial restriction to flow until the filter has become significantly clogged with dirt.

Foam

Oil-wetted polyurethane foam elements are used in some aftermarket replacement automobile air filters. Foam was in the past widely used in air cleaners on small engines on lawnmowers and other power equipment, but automotive-type paper filter elements have largely supplanted oil-wetted foam in these applications. Depending on the grade and thickness of foam employed, an oil-wetted foam filter element can offer minimal airflow restriction or very high dirt capacity, the latter property making foam filters a popular choice in off-road rallying and other motorsport applications where high levels of dust will be encountered.

Cotton

Oiled cotton gauze is employed in a small number of aftermarket automotive air filters marketed as high-performance items. In the past, cotton gauze saw limited use in original-equipment automotive air filters.

Oil Bath

An oil bath air cleaner consists of a round base bowl containing a pool of oil, and a round insert which is filled with fibre, mesh, foam, or another coarse filter media. When the cleaner is assembled, the media-containing body of the insert sits a short distance above the surface of the oil pool. The rim of the insert overlaps the rim of the base bowl. This arrangement forms a labyrinthine path through which the air must travel in a series of U-turns: up through the gap between the rims of the insert and the base bowl, down through the gap between the outer wall of the insert and the inner wall of the base bowl, and up through the filter media in the body of the insert. This U-turn takes the air at high velocity across the surface of the oil pool. Larger and heavier dust and dirt particles in the air cannot make the turn due to their inertia, so they fall into the oil and settle to the bottom of the base bowl. Lighter and smaller particles are trapped by the filtration media in the insert, which is wetted by oil droplets aspirated thereinto by normal airflow.

Oil bath air cleaners were very widely used in automotive and small-engine applications until the widespread industry adoption of the paper filter in the early 1960s. Such cleaners are still used in off-road equipment where very high levels of dust are encountered, for oil bath air cleaners can sequester a great deal of dirt relative to their overall size, without loss of filtration efficacy or airflow. However, the liquid oil makes cleaning and servicing such air cleaners messy and inconvenient, they must be relatively large to avoid excessive restriction at high airflow rates, and they tend to increase exhaust emissions of unburned hydrocarbons due to oil aspiration when used on spark-ignition engines.

How To Change Your Air Filter ?

Routine Maintenance For Cars:How To Change Your Air Filter

Clutches

2008-10-26T13:05:00.000-07:00

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How Clutches Work ?

If you drive a manual transmission car, you may be surprised to find out that it has more than one clutch. And it turns out that folks with automatic transmission cars have clutches, too. In fact, there are clutches in many things you probably see or use every day: Many cordless drills have a clutch, chain saws have a centrifugal clutch and even some yo-yos have a clutch.

Clutches are useful in devices that have two rotating shafts. In these devices, one of the shafts is typically driven by a motor or pulley, and the other shaft drives another device. In a drill, for instance, one shaft is driven by a motor and the other drives a drill chuck. The clutch connects the two shafts so that they can either be locked together and spin at the same speed, or be decoupled and spin at different speeds.

In a car, you need a clutch because the engine spins all the time, but the car's wheels do not. In order for a car to stop without killing the engine, the wheels need to be disconnected from the engine somehow. The clutch allows us to smoothly engage a spinning engine to a non-spinning transmission by controlling the slippage between them.

To understand how a clutch works, it helps to know a little bit about friction, which is a measure of how hard it is to slide one object over another. Friction is caused by the peaks and valleys that are part of every surface -- even very smooth surfaces still have microscopic peaks and valleys. The larger these peaks and valleys are, the harder it is to slide the object. A clutch works because of friction between a clutch plate and a flywheel.

Fly Wheels, Clutch Plates and Friction

In a car's clutch, a flywheel connects to the engine, and a clutch plate connects to the transmission. When your foot is off the pedal, the springs push the pressure plate against the clutch disc, which in turn presses against the flywheel. This locks the engine to the transmission input shaft, causing them to spin at the same speed.

Pressure Plate

The amount of force the clutch can hold depends on the friction between the clutch plate and the flywheel, and how much force the spring puts on the pressure plate. The friction force in the clutch works just like the blocks described in the friction section of How Brakes Work, except that the spring presses on the clutch plate instead of weight pressing the block into the ground.

Clutch Plate

Note the springs in the clutch plate. These springs help to isolate the transmission from the shock of the clutch engaging. This design usually works pretty well, but it does have a few drawbacks.

Type Of Clutches

An automatic transmission contains several clutches. These clutches engage and disengage various sets of planetary gears. Each clutch is put into motion using pressurized hydraulic fluid. When the pressure drops, springs cause the clutch to release. Evenly spaced ridges, called splines, line the inside and outside of the clutch to lock into the gears and the clutch housing. You can read more about these clutches in How Automatic Transmissions Work.

An air conditioning compressor in a car has an electromagnetic clutch. This allows the compressor to shut off even while the engine is running. When current flows through a magnetic coil in the clutch, the clutch engages. As soon as the current stops, such as when you turn off your air conditioning, the clutch disengages.

Most cars that have an engine-driven cooling fan have a thermostatically controlled viscous clutch -- the temperature of the fluid actually drives the clutch. This clutch is positioned at the hub of the fan, in the airflow coming through the radiator. This type of clutch is a lot like the viscous coupling sometimes found in all-wheel drive cars. The fluid in the clutch gets thicker as it heats up, causing the fan to spin faster to catch up with the engine rotation. When the car is cold, the fluid in the clutch remains cold and the fan spins slowly, allowing the engine to quickly warm up to its proper operating temperature.

Many cars have limited slip differentials or viscous couplings, both of which use clutches to help increase traction. When your car turns, one wheel spins faster than the other, which makes the car hard to handle. The slip differential makes up for that with the help of its clutch. When one wheel spins faster than the others, the clutch engages to slow it down and match the other three. Driving over puddles of water or patches of ice can also spin your wheels.

Car air conditioning compressor with magnetic clutch