AeroElectric-List Digest Archive

Sun 06/19/22


Total Messages Posted: 1



Today's Message Index:
----------------------
 
     1. 06:56 AM - Re: Re: Switched voltage generator (Robert L. Nuckolls, III)
 
 
 


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    Time: 06:56:03 AM PST US
    From: "Robert L. Nuckolls, III" <nuckolls.bob@aeroelectric.com>
    Subject: Re: Switched voltage generator
    At 08:57 PM 6/14/2022, you wrote: > >Buy a type "J" thermocouple and attach it to the voltage regulator. >https://www.omega.com/en-us/temperature-measurement/temperature-surface-sensors/wt/p/WTJ-6-60 >I attached a thermocouple using a regulator mounting bolt. >Monitor the thermocouple temperature somehow. I connected mine to >the Dynon D-180 in my plane. >Go flying and monitor the regulator temperature with a heavy load, >then a medium load, and then a very light load. >If the temperature goes up with the load, the regulator is a switching type. A cogent observation. I would like to suggest a refinement of terms for the rectifier/regulators common to permanent magnet alternator installations. Early in this thread, a writer expressed some confusion arising from his search for sources on 'switching regulators' . . . seems those little bits of plastic with a few connections coming out of them were not applicable to managing the energy available from an PM alternator . . . He's right. In the broader world of electron herding, SWITCHMODE regulators describe a class of devices common to electronic energy management devices found in virtually all consumer products. Things like the little 'wall warts' that quick-charge our mobile phones up to sine-wave, DC to AC inverters that might manage thousand of watts . . . and everything in between. They are the core technology of step-up, step-down converters and power suplies in our computers with 'switching' frequencies on the order of tens of thousands of Hz and higher. In the PM alternator world, the smallest devices first showed up in mini-bikes and garden tractors over 40 years ago. The simplest regulators took advantage of a common design for small alternators that rendered them impervious to damage to to 'dead shorting' of the output windings. So the easiest regulator designs would literally short out or SHUNT excess energy when a battery was fully charged. This produces a situation where the alternator is essentially loaded to full capacity 100% of the time with the regulator preventing battery overcharge (or bus over voltage) by turning unneeded energy into heat . . . both the alternator and regulator needed design features that tolerated what in other situations might be considered severe or even catastrophic overload. As magnet technology improved and electrical demands on small machines grew, larger alternators were developed . . . many configured with 3-phase windings. Tossing off excess energy with a SHUNT style rectifier/regulator became rather undesirable from an efficiency and performance standpoint. SERIES type regulators were crafted that controlled excess energy by disconnecting the alternator from the system during some portion of the AC output waveform. This produced a situation where as demands for engine driven energy went down (battery charged, system load minimal), alternator and regulator temperatures went DOWN. Obviously, the generation of heat is directly related to efficiency so the optimal design works to minimize waste heat in both machine and electronics. Getting back to the core premise of this thread, the Revmaster engine has a profound design flaw in the alternator stator which promotes the burning of windings. Bob . . . Un impeachable logic: George Carlin asked, "If black boxes survive crashes, why don't they make the whole airplane out of that stuff?"




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