A 3.4 kW, 42 V High Efficiency Automotive Power Generation System

A 3.4 kW, 42 V permanent magnet alternator based high power generation system was built and tested in the Delphi R&D laboratory. It is belt driven system with 3.37:1 pulley ratio. The size of the alternator is slightly less than the production CS-144 Lundell machine with 1/3 less inertia. For cost reasons, the controller uses a single SCR bridge rectifier. The prototype, which is capable of producing 34A/80A at idle/cruising speed, has been tested in the laboratory yielding 84.5%/70.7% efficiencies. Up to cruising speed, the system shows an improvement in full load efficiencies of 5-6 percentile points over a similar 14 V permanent magnet machine with dual SCR bridge. This efficiency improvement is due to the reduction in the converter losses as the current is reduced to one third of its 14 V values even with the same copper losses in both machines. However, beyond cruising speed the 14 V permanent magnet generator has better efficiency due to its dual bridge/dual winding configuration. This permits the windings to be switched to a lower number of turns, thus reducing copper losses (for a given load current).