The operation of the car generator regulator relay. How to test the generator regulator relay

The electrical network of any car is powered by a generator, which is driven by the engine using a belt drive. Its revolutions are constantly changing, ranging from 900 to several thousand, causing the corresponding rotation of the rotor. For the normal operation of all electrical appliances and battery charging, the voltage in the on-board network must be stable, which is provided by the relay-regulator. Being the weakest link in the power supply system, the device first of all needs to be checked when it detects problems with battery charging and other breakdowns in the car's electrical network.

Principle of operation

The oscillator voltage regulator is designed to maintain the voltage of the on-board network within the required limits for any operating mode and various generator speeds, load changes and external temperature fluctuations. It is also capable of performing additional functions - protecting the generator from overloads and emergency operation, automatically connecting the excitation windings or the generator alarm system to the on-board circuit.

The operation of any voltage regulator is based on the same principle, and is determined by the following factors:

1. Rotor speed.
2. The amount of current supplied by the generator to the load.
3. An indicator of the magnetic flux that the current of the excitation winding creates.

Higher rotor speeds determine the increase in generator voltage. An increase in the current strength on the excitation winding makes the magnetic flux stronger, and at the same time the voltage. Any voltage regulator stabilizes it by changing the excitation current. With an increase or decrease in voltage, the regulator lowers or increases the excitation current, adjusting the voltage within the required limits.

The relay-regulator itself is an electronic circuit with outputs to graphite brushes. It is installed both in the generator housing itself next to the brushes and outside it, and then the brushes are attached to the brush holder.

Faults

Most often, the relay-regulator fails for the following reasons:

1. With a good battery, there is no charging current, which is why it does not charge. This happens when the wires are poorly connected to the relay terminals or when the circuit from the generator to the battery is broken. It is eliminated by fixing the wire in the circuit, checking and adjusting the voltage regulator and the relay regulator.
2. Insufficient charging current with a discharged battery or a large one with a fully charged battery are caused by a violation of the voltage regulator adjustment. Eliminated by adjusting the device or replacing it.
3. Burning and burnout of lamps with excessive heat occurs when the adjustment of the relay-regulator is violated or the contacts are closed. It is eliminated by disconnecting and stripping the closed contacts, adjusting or replacing the voltage regulator.
4. Large discharge current after the motor stops. Occurs when the contacts of the relay-regulator close (contact sintering, armature spring breakage) or short circuit of the electric wire. It is repaired by finding and eliminating a short circuit with the battery disconnected, checking and adjusting the current limiter, opening and cleaning contacts, replacing the spring with adjusting its gap and tension.

How to check the relay regulator

A breakdown of the relay-regulator manifests itself in a systematic undercharging or overcharging of the battery. The simplest test of the device is carried out by a tester in the voltmeter mode at direct current ranging from 0 to 20V. The probes of the device with the engine off are connected to the battery terminals and record the readings of the voltmeter, which vary from 12-12.8 V depending on the state of the battery.

After the engine is started and they look at the readings of the device: the voltage should rise to 13-13.8 V, depending on the crankshaft speed. A further increase in speed should increase the voltage accordingly. So, at an average speed of rotation, it is 13.5-14 V, and at maximum it reaches 14-14.5 V. The absence of an increase in voltage after starting the motor indicates a malfunction of the relay regulator.

There is a possibility that the battery is not charging for another reason, for example, due to a malfunction in the generator itself. In order to establish a diagnosis, the relay-regulator is removed for a more accurate check using a tester and a 12-volt lamp. Additionally, you will need wires with terminals, a power supply or a charger in which you can adjust the current.

After connecting the relay to the circuit and turning on the power supply, the lamp will light up. The voltage regulator gradually increases the current and monitor the readings of the voltmeter or the scale of the connected tester. At readings up to 14.5 V, the lamp should be on, and after exceeding it, go out. If, after decreasing below 14.5, it lights up again, then the relay-regulator is working. If the work deviates in one direction or another, the relay will overcharge or not produce the necessary current for charging, which is the reason for its replacement.

In a similar way, integrated relays are checked, which are popularly called "chocolates", used on older models of domestic cars. The circuit is also connected to a power supply or charger through a light bulb, which should go out when the required voltage limit is reached. In this case, you need to pay attention to the condition of the terminals, which, if contaminated or oxidized, can create additional resistance and, if the relay is in good condition, cause a voltage loss.

Generator Regulator Relay Replacement

Relay replacement is necessary in the following cases:

1. Wear of the brushes, in which contact with the relay-regulator disappears and the generator does not work.
2. Breakdown in the circuit of the device, which causes an increase in voltage in the system.
3. Breakage of fasteners or housing, which can lead to a short circuit.

The process of replacing the device is considered using the example of the Lada-Kalina generator. Replacing the relay-regulator is associated with the dismantling of the generator, and is carried out in the following order:

1. Removing the minus terminal from the generator.
2. Dismantling the generator.

3. Snapping off the plastic clips on the cover of the generator and removing it.

4. Disconnecting the diode bridge connector.

5. Unscrewing the nut and dismantling the bushing of the contact group.

6. Unscrewing a pair of screws holding the relay-regulator.

7. Dismantling the relay itself.

8. Assembly is carried out in the reverse order.

Many people know about such a device as a generator voltage regulator, but not everyone is able to say what principles underlie its operation and how diagnostics can be carried out. It is worth noting that this device is extremely important, because it is used to stabilize the voltage at the output of the generator. Imagine how the engine works in the process of movement. Its revolutions are constantly changing, and in a wide range, ranging from 700-900 rpm, and ending with five, seven or even ten thousand. As a result, the frequency of rotation of the generator rotor also varies over a wide range. And at any speed, a stable voltage must be maintained, which will be enough to charge the battery. If there are any defects, then a thorough check of the generator voltage regulator is required.

Mechanical voltage regulators

The history of the automotive industry goes back more than a hundred years, during which time many designs have been invented and implemented that improve the performance of all units. Among them is a relay-regulator, since a modern machine will not be able to work normally without it. Initially, mechanical devices were used, which were based on an electromagnetic relay. For example, the voltage regulator of the VAZ generator of the first models was just that.

He, as it turned out later, has no pluses, quite often there are shortcomings. Moreover, the main disadvantage is low reliability due to the presence of moving contacts. They are erased over time, as the device works constantly, without stopping. In addition, sometimes it is required to carry out adjustment work, which does not have a very good effect on the operation of the car. Modernity dictates the rule according to which the machine must be serviced in a timely manner in service centers. And the driver should not be able to carry out complex repairs, he only needs the ability to drive a car and change a wheel (this is the maximum).

Electronic relay-regulators

For the reasons indicated above, electronic type voltage regulators have become widespread. Progress does not stand still, so key transistors, triacs, thyristors have replaced electromagnetic relays. They have very high reliability, since there are no mechanical contacts, instead of which there is a semiconductor crystal. Of course, the production technology of such devices should be thought out. Otherwise, the semiconductor may fail. The voltage regulator of this type of generator is checked quite simply, you just need to take into account its features.

When compared with the previous, mechanical type of relay-regulators, one feature can be seen - electronic ones are produced in the same housing with brushes. This saves space, and most importantly, facilitates the replacement and diagnostics procedure. A special feature of electronic types is the accuracy of voltage regulation. The properties of a semiconductor do not change during operation. Therefore, the voltage at the output of the generator will always be the same. But it is worth talking about the method of regulation, about how the whole process takes place. And it is quite interesting, you will have to consider in general terms the design of the generator.

What elements does a car generator consist of

The base is the body, otherwise it is called the stator. It is the fixed part of any electrical machine. The stator has a winding. In automotive generators, it consists of three parts. The thing is that a three-phase alternating voltage is generated at the output, its value is about 30 volts. The reason for using this design is to reduce ripple, since the phases overlap each other, as a result, a direct current appears after the rectifier. Six semiconductor diodes are used for voltage conversion. They are unidirectional. If a breakdown occurs, then determining this with a tester is quite simple.

But there will be no voltage at the output of the stator winding, unless one condition is taken into account - a magnetic field is needed, and a moving one. It is not difficult to make it, it is enough to wind the winding on a metal anchor and apply power to it. But now the question of voltage stabilization arises. It makes no sense to do this at the output, since the elements will need to be very powerful, because the currents are large. But here one feature of electrical machines comes to the aid of designers - if a stabilized voltage is applied to the rotor winding, then the magnetic field will not change. Consequently, the voltage at the output of the generator also stabilizes. The VAZ 2107 generator works in the same way, the voltage regulator of which operates on the same principles as those of the "tens".

Voltage Regulator Components

Modern cars are equipped with fairly simple designs. They are non-separable, two elements are combined in one housing - the regulator itself and graphite brushes that transmit the supply voltage to the rotor winding of the generator. Moreover, electronic types of devices can be of two types. For example, the VAZ-2110 generator voltage regulator manufactured in the late 90s was made on a small circuit board. Modern devices are made using a single semiconductor crystal, in which all the elements are located. You can even say that this is a small chip.

Graphite brushes are connected to the terminals of the circuit board or semiconductor element. Voltage is supplied to them from the battery through a lamp, which is necessary for diagnosing the generator. Please note that you can not put LED elements in its place, since they have no internal resistance. Roughly speaking, the incandescent lamp also works as a fuse. If the thread burns out, then the voltage supply to the rotor winding stops, the generator stops working. If the lamp lights up, then there is a breakdown. Either the brushes are worn out, or the belt is broken, but sometimes it also happens that the semiconductor diodes in the rectifier fail. In this case, it is necessary to replace the generator voltage regulator with a new one.

How to remove the regulator

If the fault is only in the voltage regulator, then there is little work to replace it. You will also need a special tool - one screwdriver is enough. It is not necessary to completely disassemble the generator, since the brushes with the voltage regulator are located on its back cover.

You don't even need to loosen the belt. It is necessary to remove the generator voltage regulator 2110 in two cases:

1. The brushes are completely worn out.
2. A breakdown has occurred in the semiconductor.

Options for checking the device will be presented below. First, disconnect the battery. The fact is that a power wire goes from it to the generator, there is no protection on it, because it is used to charge the battery. And the current consumption of this circuit is very high. There is one connector on the regulator housing, disconnect the wire from it. Now you can unscrew the two mounting bolts. After that, the generator voltage regulator can be easily removed from the rear cover. It's time to check it out.

Voltage Regulator Diagnostics

First of all, pay attention to the condition of the brushes - if their length is less than 0.5 cm, then it is necessary to change the assembly assembly. Don't invent the wheel. It makes no sense to solder new brushes, since reliability will only suffer from this. Since there are several ways to check the generator voltage regulator, it’s worth starting with the most difficult thing - removing the device. For diagnostics, you will need a power supply, at the output of which the voltage can be changed within 10-18 Volts.

You also need an incandescent lamp. Its electrical parameters are as follows: supply voltage - 12 volts, power - 2-3 watts. Serve as follows:

1. Positive output to the connector in the regulator housing (it is the only one on new samples).
2. Minus the common plate.

The incandescent lamp is switched on between two brushes. The procedure is as follows:

1. When a voltage of 12-12.5 volts is applied, the incandescent lamp should be on.
2. At voltages above 15 volts, it should go out.

If it lights up at any supply voltage, or does not light up in any of these cases, then there is a breakdown of the regulator and it needs to be replaced.

How to make a diagnosis without removal?

It is not recommended to carry out such a check, since it is not possible to assess the condition of the brush assembly. But cases are different, so even such a diagnosis can bear fruit. To work, you will need a multimeter or, if there is none, an incandescent lamp. The main thing for you is to measure the voltage in the vehicle's on-board network, to determine if there are any surges. But they can be seen while driving. For example, flashing light when the engine speed changes.

But measurements taken using a multimeter or a voltmeter with an extended scale will be more accurate. Start the engine and turn on the low beam. Connect a multimeter to the battery terminals. The voltage should not exceed 14.8 volts. But it is also impossible for it to fall below 12. If it is not in the allowed range, then there is a breakdown of the voltage regulator. It is possible that the contacts at the connection points of the device with the generator are broken, or the wire contacts are oxidized.

Modernization of the regulator circuit

How complete the battery will be charged depends on the voltage regulator. Unfortunately, the simple constructions described above have a wide range of parameters. Therefore, buying three copies of the same devices in the same store, you will get a different output voltage. And this is a fact, no one will argue. If the battery does not have enough charge, then it will lose its capacity in a short time. And it won't start the engine. You will need to restore it only with a stationary charger.

But you can install a three-level generator voltage regulator, which allows you to change the characteristics by simply switching the toggle switch. In his circuit there are two semiconductors, in which the characteristics are slightly different. This makes it possible to adjust the output voltage. When one semiconductor is turned on, 14.5 volts appears at the output, and if another is put into the circuit, it will be slightly higher. The use of such a device is relevant in the winter, when the battery capacity decreases and additional charging is required.

How to install a three-level regulator?

For this procedure, you will need a small set of tools. You need a screwdriver, heat shrink insulation, self-tapping screws, it is possible that you will need a drill with a 2-4 mm drill. So, everything is in order. First of all, you need to unscrew the two bolts that secure the brush assembly and the regulator. In its place, you need to put a new one that comes with the kit. Its difference from a simple one is that there are only brushes there, semiconductors are located in a separate block. You need to place the second node near the generator, on the car body.

To do this, make small holes for fastening. It is worth noting that the block with semiconductors needs additional cooling. Therefore, it will be necessary to install it on an aluminum radiator, only after that to make fasteners to the body elements. If sufficient cooling is not provided, then the device may fail, as well as a violation of its operation - the regulation will not occur correctly. After finishing the fastening work, connect the two nodes with wires, conduct insulation. It is advisable to fasten the connecting wires with the help of clamps-screeds to the existing bundles.

Is it possible to make a three-level regulator yourself?

If you are familiar with radio engineering, you can find a cathode and an anode on a diode, then it will not be difficult for you to make such a device yourself. The question is, does it make sense. You will need two Schottky diodes to make. If you have them, then the price of the structure will be scanty. But if you have to buy them (and it is not known at what price), then you can compare the costs with the cost of a finished three-level regulator. The three-level type generator voltage regulator circuit is simple, anyone who knows how to handle a soldering iron can repeat it.

To implement your idea, you will also need a plastic case. You can also use aluminum, it will even be better, since cooling will be more efficient. It is only desirable to cover all surfaces with a layer of insulation so that the contacts do not close to the case when driving. You will also need to install a switch that will switch semiconductor elements. The work on installing the device on a car is similar to that described in the previous paragraph. It is also worth noting that you still need to purchase a brush assembly.

conclusions

Do not neglect such a device as the voltage regulator of a car generator. The battery life depends on its quality and condition. And if there are any defects in the device, then it must be replaced. Monitor the condition of this element, if necessary, clean the contacts so that failures do not appear. The generator is located in the lower part of the engine compartment, and if there is no mudguard, then a lot of water and dirt gets on it in bad weather. And this leads to the appearance of defects, not only in the voltage regulator, but even in the stator and rotor windings. Therefore, car care is necessary for the normal functioning of all systems. And before checking the generator voltage regulator, conduct a thorough inspection and clean all structural elements from contamination.

From the article you will learn about what a voltage regulator relay for a car generator is. Also, consider the design of generator sets that are used on modern vehicles. The car has two main power sources - a generator and a battery. And they must work at the same time. With one feature - the engine starts from the battery, but when the engine is running, the on-board network is powered from both sources. In addition, the battery is recharged from the generator. It is also worth noting that car generators are very reliable units that work great in any climatic zone.

Generator device

A feature of all automotive generators is that they produce a three-phase alternating voltage. Most of the devices have right-hand rotation, in the front part there is an impeller, which is necessary for blowing air into the case and windings. A protective cover is provided on the back cover, thanks to which moisture, dust, and dirt do not get inside the device. For example, the VAZ-2110 voltage regulator is protected by this cover from foreign objects, moisture and dust.

A block of rectifiers is installed inside the generator - six diodes connected in a bridge circuit. Here you can observe the difference from the classical bridge circuit, since it becomes necessary to rectify the three-phase current. The rotor rotates inside the housing. It contains an excitation winding. In addition, there is also a winding on the body (the stator - the fixed part), it is it that generates current to power the car's on-board network and recharge the battery.

The principle of operation of the generator set

The principle of operation is based on the effects of electromagnetic induction. Let's see what these effects are. Suppose there is a conductor that is in a magnetic field. Yes, at rest you will not be able to observe anything. But if you make the conductor or the field move, then a certain potential difference will appear on the conclusions. And to put it simply, the alternating voltage. The same story in the generator - the rotor contains the excitation winding, which is energized. As a result, a magnetic field is generated. The control of the magnetic field in the generator of the seven is carried out by the voltage regulator VAZ 2107.

When the rotor rotates from the crankshaft of the engine, the magnetic field begins to move, there is a constant change of polarity. The current is transferred to the excitation winding using graphite brushes and special slip rings. This is exactly how electricity is generated, then you need to carry out rectification. And this is done with six (sometimes nine) diodes. Nine diodes are used in circuits that provide reverse voltage protection. True, in automotive technology, this switching option is not used.

How the excitation winding is powered

As you could understand, the most important thing is to power the excitation winding. And she plays a significant role in the generator. It was mentioned above that in order to transmit voltage to the winding, two nodes are required: brushes and rings. It is with their help that the voltage regulator VAZ-2110 works. Rings are located on the surface of the rotor, brushes adjoin them. This is the most vulnerable node of any generator. The brushes are made on the basis of graphite, so they are gradually destroyed by friction. In the place where the voltage regulator relay is located, there is a high level of vibration, so the possibility of its breakdown due to constant mechanical loads is not excluded.

Therefore, it is necessary to constantly monitor the condition of the brush mechanism. In addition, by adjusting the power supply of the field winding, you can get a different voltage at the output. For example, if you apply 12 volts to the rotor winding, then the same amount will be stable at the output of the generator. If 6 volts are applied, then the output will be exactly 6. It is in the rotor winding circuit that a device such as a voltage regulator relay is switched on. Moreover, its design can be both mechanical and electronic.

The purpose of the voltage regulator

Today, semiconductor devices have become very popular. For example, the VAZ-2107 voltage regulator relay consists of a semiconductor switched on in key mode. Their advantage lies in small dimensions and no need to make adjustments. You are buying a product that has optimal adjustments, it does not need intervention to ensure stable operation. It is enough just to carry out the installation on the generator, as the device will start working. Moreover, the service life of a semiconductor device is hundreds of times higher than that of a mechanical one.

The voltage regulator is necessary in order to stabilize the voltage supplied to the rotor winding. And now the essence of the process. If the excitation winding is connected to a battery without a stabilizer, then the output voltage will vary over a wide range - from 10 to 30 volts. And this is unacceptable, since the entire on-board network is designed for 12 volts. And the reason for the change in this range is the different number of revolutions of the crankshaft, as a result, the generator rotor. From this we can conclude that the higher the crankshaft speed, the higher the output voltage. From this phenomenon and allows you to get rid of the relay-regulator.

The principle of operation of the voltage regulator

In this article, only electronic designs based on semiconductors will be considered. The fact is that mechanical ones have not been used for a very long time, since they are obsolete. Therefore, a more modern voltage regulator relay circuit is now used. In addition, mechanical ones need to be constantly tuned, and all motorists do not like this. How does this device work? Everything is quite simple if you understand the principle of operation. It is worth noting that the semiconductor operates in key mode. To put it simply, the switch. When the rotor rotates, constant switching occurs - the excitation winding is either supplied with voltage from the generator output, or not.

The higher the voltage at the generator output, the more often the electronic key is activated. Therefore, when the voltage increases to a value of 13.5-14.2 volts, the rotor winding is disconnected from the power circuit. When the value drops below the mentioned limit, the power starts to flow again. Of course, the VAZ-2114 voltage regulator is configured to operate precisely in the range that was given above. Due to the fact that such a constant switching of the circuit with a high frequency occurs, the most stable voltage is generated at the output of the generator. It is worth remembering the values ​​\u200b\u200bgiven above, as they will be useful for testing relay regulators. This process will not take much time, but will allow you to accurately determine the malfunction. If you often have a breakdown of this node, then you should pay attention to the generator. It is possible that he has internal damage that needs to be repaired.

Generator drive

A few words have already been said about the fact that the generator rotor rotates from the crankshaft. And the UAZ voltage regulator is powered by the generator output. On the crankshaft is a pulley, which is connected by a belt drive to the rotor. It has a pulley similar in design, but of a smaller diameter. Most modern cars use V-ribbed multi-ribbed belts. They have reinforcement inside, the outer part is smooth, and the inner part is notched. With their help, the belt is fixed on the surface of the pulleys. It is worth noting that a lot depends on the belt tension.

In particular, the resource of the generator - if you tighten the belt strongly, then the bearing located in the front cover quickly wears out. But if you pull it weakly, then there will be a lack of current. The consequence of this is the rapid discharge of the battery. The alternator housing is fixed to the engine block using two brackets - upper and lower. They are both movable, but to adjust the belt tension, it is enough to loosen the top one. There is a stud on the body of the device, which is attached to a bracket mounted on the engine block.

How to check the voltage regulator on a car

To diagnose the power circuits, you will need a multimeter. It will need to be used in two modes - an ohmmeter and a voltmeter. If we recall what kind of electronic type voltage regulator relay circuit, it turns out that they cannot be repaired. Therefore, if the destruction of this device has occurred, you will have to install a new one. But it is worth noting that most of the regulators are made in a single housing with a brush assembly. Therefore, if the brushes are worn excessively, not only they are replaced, but also the voltage regulator.

To check the relay-regulator, you do not need to remove it, although this procedure takes several seconds in time. You will need a voltmeter. Moreover, the scale should be stretched, and the measurement limit was in the range of 12..30 Volts. The reason is that, as mentioned earlier, with a faulty stabilizer, the voltage value in the on-board network increases. But sometimes it happens that the generator refuses to work at all, there is no voltage at its output. Consequently, the voltage regulator VAZ-2106 or another car stops working.

And the entire onboard network is powered only by the battery. Please note that its capacity will last for a very short time. Especially if the car is injection (a large discharge occurs when the fuel pump is running). To finally verify this, start the engine and turn on the low beam. Connect the voltmeter to the battery terminals. The voltage value should be in the range of 13.5-14.2 Volts. If less or more, then there is a clear breakdown of the regulator or brush assembly.

Diagnostics using the power supply

But you can remove the regulator by disconnecting it from the generator. So checking the voltage regulator relay is much more efficient. Note that when carrying out any work on electrical equipment, it is necessary to disconnect the battery. You will need an incandescent lamp for diagnostics, as well as a power supply with regulated output voltage. If this is not the case, then you can use a battery charger and several AA batteries (to get a total voltage of over 15 volts). The lamp is switched on between the brushes, and plus power is supplied to the conclusions "C", "B". Accordingly, a minus must be connected to the mass output. The following conditions must be met:

• voltage up to 14 volts - the lamp is on;
• voltage over 15 volts - the lamp goes out.

If some condition is not met, then we can say that there is a breakdown of the voltage regulator.

Diagnosis of the state of the rotor winding

Unfortunately, nothing lasts forever, even such a reliable and durable unit as a generator can deteriorate. In particular, the destruction of the rotor winding (excitation) often occurs. This can happen for various reasons. First of all, the knot does not withstand the mechanical impact. In addition, dust, water, dirt can get on it, hence the decrease in resource, disruption of the generator as a whole. If the rotor winding breaks down, the generator stops generating electricity. The first sign of insufficient voltage in the network is that the direction indicators start flashing very quickly, the light dims. Consequently, the generator voltage regulator relay does not work, since it simply has nothing to feed.

To diagnose the state of the rotor winding, you must use an ohmmeter. Of course, for a rough check, you can arm yourself with a simple probe made from an incandescent lamp and an AA battery. But the effectiveness of such a diagnosis will not be extremely small. After the generator has been disassembled, take the rotor, connect an ohmmeter to the rings. It should show resistance in the range of 1.8-5 ohms. If there is a significant difference from this value, it is necessary to carry out a visual check. For example, very often there is a break in the wire that makes up the winding. Moreover, the most common place for a break is soldering it with rings.

Diagnostics of the stator winding

If the rotor winding can be checked directly on the car, however, for this you need to have long fingers and a keen eye, then the stator winding can be diagnosed only after the generator has been completely disassembled. By the way, the scooter voltage regulator is checked in the same way as on a car. But the diagnosis of the stator winding should be carried out after disassembling the entire mechanism. The reason is that the rectifier bridge will interfere with the diagnosis. So what do you do in the beginning? And you need one device - an ohmmeter. Of course, a multimeter will be the most suitable, since it can be switched to the "dialing" mode very quickly.

Check for an open in all three stator windings. To do this, connect an ohmmeter (or a multimeter in "dialing" mode) to the terminals of the windings. If no problems are found, then continue diagnosing further. Using the same device, you need to determine if there is a short circuit in the windings on the generator housing. In the same way, the presence of an interturn circuit is also checked. But this parameter is best checked using another device - a megger (for example, PDO-1). If any malfunction is found in the stator winding, then it is necessary to replace the assembly. Moreover, in some cases, when the generator requires a complete repair, it is more reasonable to replace the entire device, rather than installing new elements.

Rectifier unit diagnostics

A voltage regulator relay is connected to the rectifier output. It is advisable to check the power diodes only after disconnecting them from the terminals of the stator winding. To do this, as you understand, you need to completely disassemble the generator. Before starting the test, you need to remember the school physics course, or rather, the properties of semiconductors. You should know that diodes are only capable of passing DC current through them in one direction. It is this property that is taken as the basis of the check. To carry out the work, you need the same ohmmeter or multimeter in the "dialing" mode. Connect a diode to it, then reverse the polarity. If it conducts in one case, but not in the other, then the diode is working. If it does not conduct current in either direction, then it is out of order. Similarly, if it conducts in both directions.

Security measures

When the generator voltage regulator relay is being repaired or serviced, some precautions must be taken. In order for the operation of the generator and its components to occur in a safe mode, certain requirements must be observed. In particular, it is forbidden to operate the generator without a battery connected to the circuit. When the battery is disconnected for a short time, a sudden voltage surge occurs. As a result of this, the relay-regulator fails. Please note that when trying to start from a tow, the generator may not always produce the required voltage. In addition, if you use "lighting", you need to turn on the maximum possible number of consumers at startup.

It is also unacceptable to include any voltage sources in the on-board network, provided that the connection is made with the wrong polarity. Also, you can not connect the car's on-board network to power sources with a voltage of more than 14 volts. If welding work is carried out, then it is necessary to disconnect the battery from the network, as well as the wires going to the excitation winding. In addition, the mass of the welding machine must not be connected to the vehicle body. That's all that can be said about such a device as a voltage regulator relay. Its price in stores is 250-300 rubles, and this is not very much, given that it comes with a brush assembly together.

The alternator voltage regulator is an integral part of the electrical system of any car. With its help, the voltage is maintained in a certain range of values. In this article, you will learn about what designs of regulators exist at the moment, including mechanisms that have not been used for a long time.

Basic automatic control processes

It does not matter at all what type of generator set is used in the car. In any case, it has a regulator in its design. The automatic voltage control system allows you to maintain a certain value of the parameter, regardless of the frequency with which the generator rotor rotates. The figure shows the generator voltage regulator relay, its circuit and appearance.

Analyzing the physical basis on which the generator set operates, it can be concluded that the output voltage increases if the rotor speed becomes higher. It can also be concluded that voltage regulation is carried out by reducing the current supplied to the rotor winding with an increase in rotation speed.

What is a generator

Any car generator consists of several parts:

1. A rotor with an excitation winding around which an electromagnetic field is created during operation.

2. A stator with three windings connected according to the "star" scheme (an alternating voltage is removed from them in the range from 12 to 30 Volts).

3. In addition, the design has a three-phase rectifier, consisting of six semiconductor diodes. It is worth noting that the relay-voltage regulator of the VAZ 2107 generator in the injection system) is the same.

But the generator will not be able to work without a voltage regulation device. The reason for this is the change in voltage in a very large range. Therefore, it is necessary to use an automatic control system. It consists of a comparison device, control, executive, master and special sensor. The main element is the regulator. It can be either electrical or mechanical.

Generator operation

When the rotation of the rotor begins, a certain voltage appears at the output of the generator. And it is fed to the excitation winding by means of an adjustment organ. It is also worth noting that the output of the generator set is connected directly to the battery. Therefore, voltage is constantly present on the excitation winding. As the rotor speed increases, the generator set output voltage begins to change. The relay-voltage regulator of the Valeo generator or any other manufacturer is connected to the generator output.

In this case, the sensor captures the change, sends a signal to the comparing device, which analyzes it, comparing it with the specified parameter. Next, the signal goes to the control device, from which it is fed to the Regulator, which is able to reduce the value of the current that flows to the rotor winding. As a result, the voltage at the output of the generator set decreases. Similarly, the above parameter is increased in case of a decrease in the rotor speed.

Two Level Regulators

The two-level automatic control system consists of a generator, a rectifier element, and a storage battery. It is based on an electric magnet, its winding is connected to the sensor. The driving devices in these types of mechanisms are very simple. These are regular springs. A small lever is used as a comparing device. It is mobile and performs switching. The actuating device is the contact group. The regulator is a constant resistance. Such a relay-generator voltage regulator, the circuit of which is given in the article, is very often used in technology, although it is obsolete.

The operation of a two-level regulator

When the generator is running, a voltage appears at the output, which is supplied to the winding of the electromagnetic relay. In this case, a magnetic field arises, with its help the lever arm is attracted. The latter is acted upon by a spring; it is used as a comparator. If the voltage becomes higher than expected, the contacts of the electromagnetic relay open. In this case, a constant resistance is included in the circuit. Less current is applied to the excitation winding. The voltage regulator of the VAZ 21099 generator and other domestic and foreign cars works on a similar principle. If the output voltage decreases, then the contacts are closed, while the current strength changes upwards.

Electronic regulator

Two-level mechanical voltage regulators have a big drawback - excessive wear of the elements. For this reason, instead of an electromagnetic relay, they began to use semiconductor elements operating in a key mode. The principle of operation is similar, only the mechanical elements are replaced by electronic ones. The sensitive element is made on which consists of fixed resistors. A zener diode is used as a master device.

The modern relay-voltage regulator of the VAZ 21099 generator is a more advanced device, reliable and durable. The actuating part of the control device functions on transistors. As the voltage at the generator output changes, the electronic key closes or opens the circuit, if necessary, add additional resistance. It is worth noting that two-level regulators are imperfect devices. Instead, it is better to use more modern developments.

Three-level regulation system

The quality of regulation of such structures is much higher than that of the previously considered ones. Previously, mechanical designs were used, but non-contact devices are more common today. All elements used in this system are the same as those discussed above. But the principle of operation is slightly different. First, voltage is applied through a divider to a special circuit in which information is processed. It is possible to install such a generator voltage relay-controller ("Ford Sierra" can also be equipped with similar equipment) on any car if you know the device and the connection diagram.

Here the actual value is compared with the minimum and maximum values. If the voltage deviates from the value that is set, then a certain signal appears. It is called a mismatch signal. With its help, the current strength supplied to the excitation winding is regulated. The difference from a two-level system is that there are several additional resistances.

Modern voltage regulation systems

If the relay-voltage regulator of the Chinese scooter generator is two-level, then more advanced devices are used on expensive cars. Multilevel control systems can contain 3, 4, 5 or more additional resistances. There are also tracking systems for automatic control. In some designs, you can refuse to use additional resistances.

Instead, the frequency of operation of the electronic key increases. It is simply impossible to use circuits with an electromagnetic relay in servo control systems. One of the latest developments is a multi-level control system that uses frequency modulation. In such designs, additional resistances are needed, which serve to control the logic elements.

How to remove the relay-regulator

Removing the generator voltage regulator relay ("Lanos" or your domestic "nine" is not important) is quite simple. It is worth noting that when replacing the voltage regulator, only one tool is required - a flat or Phillips screwdriver. It is not necessary to remove the generator or belt and its drive. Most of the devices are located on the back cover of the generator, and are combined into a single unit with a brush mechanism. The most frequent breakdowns occur in several cases.

Firstly, with the complete erasure of graphite brushes. Secondly, during the breakdown of a semiconductor element. How to check the regulator will be described below. When removing, you will need to disconnect the battery. Disconnect the wire that connects the voltage regulator to the generator output. By unscrewing both fixing bolts, you can pull out the body of the device. But the voltage regulator relay has an outdated design - it is mounted in the engine compartment, separately from the brush assembly.

Device check

The relay-voltage regulator of the VAZ 2106 generator, "kopecks", foreign cars is checked in the same way. As soon as you remove, look at the brushes - they should have a length of more than 5 millimeters. In the event that this parameter is different, you need to replace the device. To carry out diagnostics, you need a constant voltage source. It is desirable to be able to change the output characteristic. As a power source, you can use the battery and a pair of finger batteries. You also need a lamp, it must work from 12 volts. You can use a voltmeter instead. Connect the positive from the power supply to the voltage regulator connector.

Accordingly, connect the negative contact to the common plate of the device. Connect a light bulb or voltmeter to the brushes. In this state, voltage should be present between the brushes if 12-13 volts are applied to the input. But if you apply more than 15 volts to the input, there should be no voltage between the brushes. This is a sign that the device is working. And it doesn’t matter at all whether the voltage regulator of the VAZ 2107 generator or another car is being diagnosed. If the control lamp lights up at any voltage value or does not light up at all, then there is a node malfunction.

conclusions

In the electrical system of a car, the voltage regulator of the Bosch generator (as, indeed, of any other company) plays a very important role. As often as possible, monitor its condition, check for damage and defects. Cases of failure of such a device are not uncommon. In this case, at best, the battery will be discharged. And at worst, the supply voltage in the on-board network may increase. This will lead to the failure of most of the consumers of electricity. In addition, the generator itself may fail. And its repair will cost a tidy sum, and given that the battery will fail very quickly, the costs are completely cosmic. It is also worth noting that the Bosch generator voltage regulator relay is one of the leaders in sales. It has high reliability and durability, and the characteristics are as stable as possible.

Good day! Today, we will continue the topic of small electrical mechanisms (started in the last publication), which are of paramount importance in the normal operation of the vehicle. The object of our conversation will be such a mechanism as a generator voltage regulator relay (RRNG). At first glance, it may seem to you that you have not yet met such a detail, but this is probably not the case. If you had a chance to personally remove the generator, I'm sure you noticed a certain device on its back wall, fixed on two bolts, that's what it is. I hope you understand what I often mean, brushes are also present on it.

The failure of this relay, a frequent case, I personally had some kind of black bar, I changed them one by one and so 5-6 times. It was at that time that I had to learn more about him, thanks to which I managed to solve the problem. Okay, let's not talk about me, it's better about a relay that will restore the required level of charging current coming from the generator and prevent battery damage. But for starters, well, you can’t ignore the generator itself, because RRNG is one of its main elements.

Automobile generator and its device

Absolutely any car generator produces only three-phase alternating voltage. This happens by rotating the rotor, modern models mostly spin to the right, but there are exceptions. Before you understand where that voltage comes from, consider all the details that make up the generator:

• Impeller - installed on the outside of the generator, in the front of the housing, serves to blow and, accordingly, cool the winding.
• Rear housing cover - closes access to the internal elements of the unit of dust, dirt and other contaminants. In addition, a protective cover can be installed on it, if one exists, the RRNG is installed behind it, as on the VAZ 2110.
• Rectifier block - consists of six diodes connected to each other in a bridge circuit.
• Rotor and excitation winding - rotates around its axis directly in the housing creating a magnetic field.
• The stator is also a body, three windings are placed on its body, interconnected with their help, it is possible not only to recharge the battery, but also to provide the necessary power to the car's on-board network.
• Relay-generator voltage regulator - maintains the voltage in a certain range.

The scheme for generating alternating voltage by the generator is as follows: the rotor, rotating (and with it the magnetic field) from the efforts of the crankshaft, constantly changes polarity, this happens due to the fact that the excitation winding is always under low voltage, because the generator is connected to the battery. Rotating around its axis, the rotor on the terminals forms an alternating current, which is supplied to the winding by excitation. That is, you understand, yes, the belt on the generator is put on so that the rotor spins, in a standing position, it is not able to create a magnetic field. Graphite brushes and slip rings are directly involved in this process.

When the electricity is generated, it must be rectified, a diode bridge takes over. And everything would be fine, but with an increase in the speed of the rotor, the current also increases, and here the relay voltage regulator of the generator, connected to the output of the unit, enters the main stage. It reacts to all changes and sends the data to the comparing device, where the standard readings are analyzed with the received ones. After that, the signal is sent to the control device, from where it is fed to the actuator.

Please note: in the event of a decrease in the rotor speed, RRNG increases the current level to the required output value.

weak point of the generator

I think it’s clear now whether you have an injector or even a diesel engine, this relay will definitely be present on the generator, otherwise the latter simply won’t be able to perform its functions without it. So, brushes, rings and the RRNG itself are the most vulnerable node in the generator. Why? Everything is very simple where the regulator is located, a constant high level of vibration, from this the probability of breakdown increases significantly. Well, the brushes, they are graphite, which means they will definitely be erased over time.

Therefore, you, as a responsible driver, must constantly monitor the performance of the generator voltage regulator relay or problems cannot be avoided.

Now in more detail - the purpose and principle of operation of the RRNG

In order for you to understand exactly why there is a regulator in the generator, I will give a small example. Suppose, dear friends, we take and connect the excitation winding to the power source, without RRNG, what will happen with the voltage? How do you think? Do not know? And I'll tell you the current level will jump in a wide range, somewhere in the range of 10-30 volts. Imagine if such a voltage comes out of the generator, there is a radio tape recorder, and all the electrics will burn out, because it is designed for exactly 12 volts. Why this happens, I have already said - the more often the crankshaft rotates, and with it the rotor, the higher the voltage. The generator voltage regulator relay eliminates the possibility of too high current output, now I think it’s clear.

Let's go further, consider the principle of operation of the electrical RRNG, although mechanical ones are still found, they cannot withstand criticism for a long time. By and large, the relay-regulator is a kind of on/off switch. See for yourself, the fixed voltage level limit ranges from 13.5-14.2 volts. That is, when the current increases to these indicators, the regulator disconnects the rotor winding from the common circuit and, vice versa, connects it when it decreases. Thus, the circuit is constantly switched at a high frequency, so that the generator is able to generate a stable voltage.

Varieties of the relay-regulator

For any car, including VAZ, you can buy RRNG of various types. And although recently semiconductor models have been especially popular, we will consider all existing ones.

• Two-level - despite the fact that this type of relay is considered obsolete, many motorists continue to use it. The "foundation" of such devices is an electromagnet connected to the sensor by a winding. The springs perform the function of a master device, and a small movable lever acts as a comparator, which performs switching. Constant resistance - the control body, the contact group - the actuator. The main disadvantage of two-level sensors is their short service life, both motorists and experts talk about this.

• Electronic - they, as you probably already understood, are also called semiconductor. These are more advanced and durable devices, we have already talked about them before.

• Three-level regulator - the design of the mechanism is not much different from those described above, only in that there are several additional resistances.

• Multilevel - mechanisms equipped with 3, 4 and even 5 additional resistances, there are options that can function in a tracking mode. Such models are one of the latest creations of the developers, hence the slightly corresponding price.

On average, a running semiconductor relay-regulator will cost you at least 300-400 rubles. And my advice to you, buy two at once, let it be in reserve, because this is one of those details that will not interfere with the driver on the road.

Installation and diagnostics of RRNG

Armed with an ordinary flat screwdriver, you will certainly be able to install the relay-regulator on the generator and remove it from there. Please note: you do not need to relax the belt to dismantle the generator, you do not need to remove it. First of all, do not forget to fold the positive terminal on the battery, you never know, so as not to close anything. Then everything is simple: disconnect the "mother" of the regulator from the "folder" and unscrew the two bolts, after which you can remove the mechanism itself. Next, you need to check it for a malfunction.

Immediately make sure that the brushes are of normal length (at least 5 mm). And only then get a voltmeter, or if there is none, an ordinary incandescent lamp will do and, most importantly, do not forget to grab a couple of AA batteries, their connection is a must! The latter will help to get a total voltage of more than 15 volts, now you will understand what it is for. So, we connect the “plus” with an output to the RRNG, we fix the minus on the device case. We fix the lamp or voltmeter that you have there between the brushes, we don’t touch the batteries yet, we use only the battery. In this state, the voltage between the brushes should be!

If you add two batteries to the circuit and get a total voltage of more than 15 volts, there should be no voltage between the brushes! Otherwise, feel free to send your regulator to the trash!

Summing up, I demand from you, as from responsible motorists - always monitor the technical condition of the relay-regulator. In another case, do not be surprised if at one fine moment you fail, at least - the battery, maximum - the entire on-board system. I hope we understand each other. If so, I'm leaving, if not, read the article again! See you soon!