Alternator tester

• US 6,466,025 B1
• Filed: 01/13/2000
• Issued: 10/15/2002
• Est. Priority Date: 01/13/2000
• Status: Expired due to Term

• Current Assignee: Midtronics Incorporated
• Original Assignee: Midtronics Incorporated
• Inventors: Klang, James K.
• Primary Examiner(s): Le, N.
• Assistant Examiner(s): Hamdan, Wasseem H.
• Application Number:
  US09/483,623
• Time in Patent Office: 1,006 Days
• Field of Search: 324/426, 324/772, 324/429, 320/104, 320/134, 322/28
• US Class Current: 324/429
• CPC Class Codes: G01R 31/34 Testing dynamo-electric machines

Abstract

The present invention provides a straightforward diagnostic system and testing procedure that gives relevant data on the performance of the charging system in a battery-based electrical system. The overall method for testing the alternator comprising determining a threshold voltage of the battery-based electrical system, powering the alternator, determining a charging current generated by the alternator, and determining a charging voltage generated by the alternator. In this manner, an apparatus and system capable of rapidly determining whether a vehicle charging system is operating properly are disclosed.

Claims

1. An apparatus for testing an alternator in a battery-based electrical system, the apparatus comprising:

a voltage sensor for adapted for attachment to the battery-based electrical system for measuring voltage of the battery-based electrical system;

a charging current sensor adapted for attachment to the battery-based electrical system for measuring current charged to the battery-based electrical system;

a discharging current sensor adapted for attachment to the battery-based electrical system for measuring current discharged from the battery-based electrical system;

a variable power supply adapted for attachment to the battery-based electrical system for varying the charging conditions of the battery-based electrical system;

a variable load adapted for attachment to the battery-based electrical system for varying the discharging conditions of the battery-based electrical system; and

a system controller for use in controlling the variable power supply and load and for measuring the current and voltage generated by the alternator under the varying charging and discharging conditions of the battery-based electrical system.

2. In a battery-based electrical system comprised of a battery and an alternator, a method for testing the alternator comprising:

activating the battery-based electrical system at a nominal operating load level;

applying an external charge voltage and an external charge current to the battery-based electrical system;

adjusting the external charge voltage in steps of predetermined magnitude until the external charge current is reduced to substantially zero;

removing the external charge voltage and the external charge current from the battery-based electrical system;

measuring the threshold charging voltage of the battery-based electrical system;

powering the alternator;

applying an external discharge load to the battery-based electrical system;

adjusting the external discharge load in steps of predetermined magnitude until the charging voltage generated by the alternator is less than or equal to the threshold voltage;

determining the charging current generated by the alternator by measuring the external load current;

removing the external discharge load from the battery-based electrical system;

applying an external charge voltage and an external charge current to the battery-based electrical system;

adjusting the external charge voltage in steps of predetermined magnitude until the external charge current generally stabilizes; and

determining the charging voltage generated by the alternator by measuring the battery-based electrical system voltage.

3. In a battery-based electrical system comprised of a battery and an alternator powered by an engine of a vehicle, a method for testing the alternator comprising:

determining a threshold charging voltage of the battery-based electrical system which is representative of a voltage supplied by the alternator which is sufficient to support nominal vehicle electrical system loads without charging the battery;

powering the alternator;

determining alternator charging current generated by the alternator representative of current supplied by the alternator during operation of the engine of the vehicle; and

determining alternator charging voltage generated by the alternator representative of a voltage at which the alternator attempts to charge the battery at vanishing current.

4. The method as recited in claim 3 wherein the step of determining the threshold charging voltage of the battery-based electrical system comprises:

activating the battery-based electrical system at a nominal operating load level;

applying an external charge voltage and an external charge current to the battery-based electrical system;

adjusting the external charge voltage in steps of predetermined magnitude until the external charge current is reduced to substantially zero;

removing the external charge voltage and the external charge current from the battery-based electrical system; and

measuring the threshold charging voltage of the battery-based electrical system.

5. The method as recited in claim 3 wherein the step of determining the charging current generated by the alternator comprises;

applying an external discharge load to the battery based electrical system;

adjusting the external discharge load in steps of predetermined magnitude until the charging voltage generated by the alternator is less than or equal to the threshold voltage; and

determining the charging current generated by the alternator by measuring the external load current.

6. The method as recited in claim 3 wherein the step of determining the charging voltage generated by the alternator comprises:

applying the external charge voltage and an external charge current to the battery-based electrical system;

adjusting the external charge voltage in steps of predetermined magnitude until the external chrage current generally stabilized; and

determining the charging voltage generated by the alternator by measuring the battery-based electrical system voltage.

7. The method of claim 3 including determining whether the battery has enough power to start the engine of the vehicle prior to testing the alternator.

8. The method of claim 3 including determining if the battery is sufficiently charged to provide an acceptable alternator test by charging the battery.

9. The method of claim 3 including instructing an operator to start the engine of the vehicle after determining an open circuit voltage of the battery.

10. The method of claim 9 including monitoring a battery voltage to detect starting of the engine.

11. The method of claim 3 wherein alternator charging voltage is determined only if the alternator charging current is significant.

12. The method of claim 3 including identifying the alternator as acceptable based upon the alternator charging voltage and the alternator charging current.

13. The method of claim 12 wherein identifying the alternator as acceptable is further based upon temperature.

14. The method of claim 12 wherein identifying the alternator as acceptable is further based upon alternator specifications.

15. The method of claim 3 including instructing an operator to repeat the steps of claim 3 at a greater engine RPM if the alternator current is below a minimum level.

16. An alternator tester configured to test an alternator in accordance with the method of claim 3.

17. An alternator tester for use in connection with a battery-based electrical system comprised of a vehicle battery and an alternator powered by an engine of a vehicle, the alternator tester comprised of a variable power supply and a variable load in communication with a system controller, the system controller having instructions to perform the steps of:

testing the vehicle battery to determine whether the battery is capable of delivering and accepting adequate charge; and

testing the alternator to determine whether the alternator is capable of delivering acceptable power to the battery-based electrical system of the vehicle and wherein the testing includes controlling the variable power supply and the variable load.

18. The alternator tester recited in claim 17, wherein the step of testing the alternator comprises the steps of:

determining a threshold voltage of the battery-based electrical system which is representative of a voltage supplied by the alternator which is sufficient to support nominal vehicle electrical system loads without charging the battery;

powering the alternator;

determining a charging current generated by the alternator representative of current supplied by the alternator during operation of the engine of the vehicle; and

determining a charging voltage generated by the alternator representative of a voltage at which the alternator attempts to charge the battery at vanishing current.

19. The alternator tester recited in claim 18, wherein the step of determining the threshold voltage of the battery-based electrical system comprises the steps of:

activating the battery-based electrical system at a nominal operating load level;

applying a charge voltage and a charge current with the variable power supply to the battery-based electrical system;

adjusting the charge voltage in steps of predetermined magnitude until the charge current is reduced to substantially zero;

removing the charge voltage from the battery-based electrical system; and

measuring the threshold charging voltage of the battery-based electrical system.

20. The alternator tester recited in claim 18, wherein the step of determining the charging current generated by the alternator comprises the steps of:

applying a discharge current to the battery-based electrical system using the variable load;

adjusting the discharge current in steps of predetermined magnitude until the charging voltage generated by the alternator is less than or equal to the threshold voltage; and

determining the charging current generated by the alternator by measuring the external load current.

21. The alternator tester recited in claim 18, wherein the step of determining the charging voltage of the alternator comprising the steps of:

applying the charge voltage and a charge current to the battery-based electrical system using the variable power supply;

adjusting the charge voltage in steps of predetermined magnitude until the charge current generally stabilizes; and

determining the charging voltage generated by the alternator by measuring the battery-based electrical system voltage.

22. The method of claim 17 including determining whether the battery has enough power to start the engine of the vehicle prior to testing the alternator.

23. The method of claim 17 including determining if the battery is sufficiently charged to provide an acceptable alternator test by charging the battery.

24. The method of claim 17 including instructing an operator to start the engine of the vehicle after determining an open circuit voltage of the battery.

25. The method of claim 24 including monitoring a battery voltage to detect starting of the engine.

26. The method of claim 18 wherein the alternator charging voltage is determined only if the alternator charging current is significant.

27. The method of claim 20 including identifying the alternator as acceptable based upon the alternator charging voltage and the alternator charging current.

28. The method of claim 27 wherein identifying the alternator as acceptable is further based upon temperature.

29. The method of claim 27 wherein identifying the alternator is acceptable is further based upon alternator specifications.

30. The method of claim 18 including instructing an operator to repeat the steps of claim 18 at a greater engine RPM if the charging current is below a minimum level.

31. An alternator tester configured to implement the method of claim 17.