navigation

Design Aftermarket Reliability Applications Home

space

 

Design Tips
our rugged components provide trouble-free performance in all kinds of weather and conditions
Product Solutions
Our regulator solutions offer:
  • True RMS trimming on no-battery applications
  • Single or three-phase rectified
  • Shunt, series or excited field
  • Temperature compensation to satisfy lead acid battery requirements
  • Low leakage current
  • Three-phase designs
Tympanium works closely with our OEM customers to understand the overall application requirements for loads, temperatures, cooling, and alternator characteristics to assure optimal regulator design for the engine, vehicle or system being developed.

Permanent magnet (PM) alternators are usually controlled with either a shunt or a series regulator. In a few applications, small alternators are controlled by simply using a rectifier and the connected electrical load. This is not a practical approach for most systems with more than a 100 watt capability. All PM alternators can be series-regulated, though the costs to meet certain technical requirements can be high. Some PM alternators must not be shunt-regulated, or else serious damage will result.

Here are a few PM Alternator / Regulator - Rectifier basics:

  • A rectifier converts an AC wave form to a DC wave form with ripple. A good battery or large capacitor properly connected across the output will reduce the ripple.
  • A regulator's function is to reduce the average current through the rectifier to the amount that is necessary to satisfy the operating loads at any given time.
  • Regulators using silicon controlled rectifiers (SCR's) may be either series (stops current flow) or shunt (diverts current flow). Shunt regulators adapt more readily to situations where a battery may not be required but where regulation for lights or other loads is required.
  • When the voltage across the battery rises above a regulator's set point (nominally 14 volts),
    • the shunt SCR's are turned on as necessary to divert any excess available current away from the battery and/or its loads.
    • the series SCR's are turned off as necessary to block any excess available current from passing to the battery and/or its loads.
  • Do not substitute shunt regulators for series regulators without first understanding the alternator characteristics or the engine manufacturer's recommendation. Otherwise alternator/regulator damage may result.
  • If measurements are made in applications where there is neither a battery nor a large capacitor across the regulator output, a standard DC meter will give erroneous readings. Under these circumstances a true rms meter with a crest factor of at least six that measures the AC plus DC components of the wave form is needed.
  • In order to better satisfy the charging needs of a typical lead acid battery, most regulators are designed with a temperature coefficient to approximate the battery's temperature-sensitive characteristics.

The following comparisons presume that undervoltage (lack of sufficient charge) is the preferred failure mode to an overcharge condition (excessive gassing, sometimes referred to as "boilover") where sulfuric acid leaks and explosive gases may accumulate.

Shunt vs. Series Regulation Comparison

Shunt
Often the preferred regulator for alternators that will not develop excessive current when shunted.
Series
Often found in lower-cost solutions to controlled rectification.
Advantages vs. series Disadvantages Advantages vs. shunt Disadvantages
Peak voltages on the alternator; connector and regulator are usually lower. When the engine is running, full alternator current is flowing in the stator, regulator, and their connections. Only the necessary load current runs at any time. The result is less heating when operated below 2/3 of full electrical load.v Operating peak voltages are high, although open circuit voltages may be lower than in shunt-controlled alternators.
Overheated SCR fails safe-shunting results in undercharge. More heat is developed with low (below 2/3 of full) loads. No frills half wave DC series can be quite inexpensive. 20% more regulator heat is produced at full output.
Simple and reliable control circuit. SCR's isolated resulting in 50% higher thermal impedance. Fewer normally active power semiconductors. Difficult and expensive to control AC-only loads.
Basic load dump protection is inherent in the design. Rectifiers produce a recovery spike on B+. No stator thermal recovery when going from low output to full output current. B+ load dump protection circuit can be costly.
Much easier to control AC-only or "no-battery" loads.     Electrical noise suppression requires larger and more expensive components.
Small, relatively inexpensive noise suppression components.     Overheated SCR fails unsafe - full, uncontrolled alternator output.