ALTERNATOR TEST TABLE

Abstract

This invention relates to an alternator test bench system that enables the testing of electrical and electronic components used in vehicles, such as alternators, batteries, and inverters, under load in a laboratory environment that mimics real operating conditions. The system includes at least one electric motor, a motor shaft connected to this motor, bearings, a belt-pulley drive mechanism, an alternator mounting bracket, a motor front mounting bracket, and a bearing mounting bracket, along with a test bench body that supports all components. The alternator is driven by the electric motor via a belt-pulley mechanism, and the electrical energy it produces is used to charge the batteries during the test. The inverter is operated simultaneously with the alternator and battery under load, and its electrical and thermal behavior is analyzed within the same test cycle.This allows for the integrated validation of alternator, battery, and inverter components on a single platform, without running the vehicle. Figure 1.

Description

1 TARIFF ALTERNATOR TEST TABLE TECHNICAL FIELD This invention relates to alternators and related electrical and electronic components used in vehicles. an alternator test 5 for testing under load in a laboratory environment It relates to the table. The invention is particularly relevant in diesel vehicles and electric vehicle architectures. components used such as alternators, inverters, electric motors and batteries performance validation similar to real working conditions It involves a test system that allows for the simulation of electricity in this way. The system is electrical. motor, motor shaft, pulley-belt drive mechanism, alternator, inverter and battery 10 the components are run on a controlled test bench and under load It allows for the measurement of performance data. PREVIOUS TECHNIQUE In the current technical field, alternators, inverters, and electrical systems used in vehicles are 15. Performance verification tests for motor-battery combinations are generally costly. This is carried out in laboratory environments, particularly by institutions like TÜBİTAK. Dynamometer (dyno) systems found in laboratories measure specific alternators. To measure current and voltage generation performance under loads. It is used. However, 20 studies conducted on such professional testing infrastructures... measurements are problematic due to both high testing fees and a lack of flexibility in scheduling. Operational challenges for manufacturers due to constraints such as these It constitutes. Current technology generally involves external testing of the alternator under load. costly and difficult-to-plan dynamometer systems found in laboratories It requires this. Also, known mechanisms involve belt-pulley transmission of the alternator. accurately replicating the typical vehicle architecture through which it is driven in a laboratory environment. It is unable to simulate; simultaneous testing of other vehicle components such as inverter and battery. that does not allow it. 30 Even if car manufacturers have simple test setups used within their own organizations However, these solutions are often only applicable to idle speed tests of the alternator or low-speed tests. It is limited to multi-level load simulation. A significant portion of these systems; 2 It is unable to simulate the alternator's operation under a real engine load. The inverter is unable to reliably measure current-voltage performance under load. simultaneous testing of multiple components such as electric motors and batteries This does not allow for it. In addition, existing solutions do not provide vehicle-mounted working conditions. an integrated mechanical-electrical test capable of reproducing the process in a laboratory environment 5 It does not have a specific architecture. In particular, the inverter exhibits thermal behavior under load. monitoring the charge status of the batteries during the testing period, and the electric motor. the alternator is driven and the shaft-pulley-belt transmission elements are coordinated. Compact and integrated test systems that meet requirements such as operational efficiency. It is limited in the literature. 10 Therefore, currently, vehicle manufacturers are selecting alternators to be used in new projects. We are dependent on external testing organizations to validate inverter and motor components. This remains the case, and this has negative effects on both cost and development time. It creates. 15 A BRIEF DESCRIPTION OF THE INVENTION The primary purpose of this invention is to replace components such as alternators, batteries, and inverters used in vehicles. load electrical and electronic components in an environment similar to real operating conditions. low-cost, compact, and 20-inch panels that allow their performance to be tested. The goal is to provide an integrated alternator test bench. One purpose of the invention is to drive a belt-pulley mechanism powered by an electric motor. The alternator, driven by this method, is subjected to different loads in a laboratory environment. subjected to scenarios and the voltage / current production characteristic correctly 25 testing the alternator under realistic load conditions with the aim of evaluating it. The aim is to ensure that it is done. One aim of the invention is to improve the inverter's heating, efficiency, and electrical response under load. its performance integrated into the alternator test, i.e., a single test scenario 30 by enabling measurement within the inverter's electrical and electrical parameters in the same test cycle. The aim is to enable monitoring of its thermal behavior. 3 One purpose of the invention is to allow batteries positioned on the test bench to absorb the current produced by the alternator. By ensuring simultaneous charging under the voltage, the battery charging behavior is controlled. The changes and system interactions can be monitored, allowing for better tracking of battery load. The scenario involves testing the charging performance. One purpose of the invention is to adapt in-vehicle electrical systems such as alternators, motors, inverters, and batteries. Simultaneous testing of the components; thus providing insight into the vehicle's electrical architecture. It is possible to identify failure, performance loss, or incompatibility scenarios. by enabling integrated validation of all components on a single table. It is a verification. 10 One purpose of the invention is to create alternators / inverters / batteries for use in electric vehicles. Early-stage validation and field testing of combinations are necessary. Rapid analysis of encountered component problems in a laboratory environment. enabling rapid validation and root cause identification for new vehicle projects. The aim is to enable analysis to be performed. BRIEF DESCRIPTION OF THE FIGURES Figure 1 shows a general overview of the alternator test bench layout, which is the subject of the invention. It shows its appearance. 20 REFERENCE NUMBERS GIVEN IN THE FIGURES 1- Alternator 2- Electric motor 3- Motor shaft 25 4- Bearing 5- Belt 6- Pulley 7- Engine front mounting bracket 8- Bearing mounting bracket 30 9- Alternator mounting bracket 10- Test table 11- Battery 12- Inverter 4 DETAILED DESCRIPTION OF THE INVENTION This invention is used for electrical devices such as alternators (1), inverters (12) and batteries (11) used in vehicles. electronic components in the laboratory under conditions similar to those of a real vehicle. a compact, benchtop test setup that enables testing under load in the environment It is related to. The system subject to the invention consists of a mechanical drive mechanism, transmission components, 5 electrical load circuit and test bench (10) body carrying these elements including functionally related and integrated components It consists of. The test table (10) constitutes the main supporting structure of the system in question and all 10 It ensures the mechanical fixation of the components. On the test table (10), The components that perform the system's drive and testing functions are positioned. At least one electric motor (2), alternator (1), on the upper part of the test table (10), motor shaft (3), belt (5), pulleys (6), bearings (4) and motor front mounting bracket 15 (7), bearing mounting bracket (8) and alternator mounting bracket (9) are located; bottom In this section, the batteries (11) and the inverter (12) are located. This arrangement, ensuring the system operates in a balanced and safe manner, both mechanically and electrically. It is designed to provide a test table (10) which is a rigid platform that dampens vibrations. It has a frame structure and maintains the stability of all components throughout the testing period. 20 The electric motor (2) is the primary drive element that provides mechanical torque to the alternator (1). The electric motor (2) has adjustable speed and revolution depending on the test scenario. It is connected to a power supply to operate at its specified values. Thus, the alternator... (1) Behavior can be simulated under different working conditions. 25 The rotational motion produced by the electric motor (2) is transmitted through the motor shaft (3). The transmission is transmitted to the system's transmission mechanism. The motor shaft (3) passes through the bearings (4). mounted on a bearing and with the help of the bearing connection bracket (8) on the test table (10) It is fixed. Thanks to this structure, the motor shaft (3) runs smoothly with low friction and 30 It performs a steady rotational motion. The drive pulley (6) mounted on the motor shaft (3) and the alternator (1) The pulley is connected to the belt (5). This belt-pulley mechanism; It simulates the alternator drive principle in vehicles in a laboratory environment. It ensures that the torque transmitted to the alternator (1) is transferred in a controlled manner, speed and load It allows for the realistic establishment of relationships. In this respect, the system, Unlike classic test setups where the alternator (1) is directly connected, in-vehicle It offers a unique structure that imitates the belt (5) pulley (6) architecture. 5 Motor front mounting bracket (7), electric motor (2) towards the test table (10) It enables the bearing mounting bracket (8) to be fixed in position and angle. (3) It provides alignment and stability by maintaining the position of the bearings (4) on which it is supported. The alternator mounting bracket (9) is suitable for the alternator (1) test bench (10). fastening in position and correct adjustment of belt tension This makes it possible. These brackets work together to maintain the mechanical integrity of the system. It reduces vibrations and ensures safe working conditions during long-term testing. The alternator (1) is the basic test component of the system and is driven by the electric motor (2) via a belt. It is driven via (5). 15 During the test, the current and voltage values ​​produced by the alternator under different load conditions were recorded. voltage regulation behavior, heating characteristics, response to load changes Dynamic responses are measured and analyzed in a laboratory setting. This allows us to determine the alternator's... (1) The actual operating characteristics of the vehicle were tested again on the test bench (10) 20 is created. The batteries (11) located in the lower part of the test table (10) body, the alternator (1) It is charged with the electrical energy it produces. In this way, the charging behavior of the batteries (11) is determined by the voltage. Growth curves and battery dynamics under load can be monitored throughout the test cycle. 25 The batteries (11) also provide a realistic electrical load for the alternator (1). The inverter (12) is integrated into the electrical test circuit of the system and the alternator (1) and operates simultaneously with the batteries (11). The inverter's (12) thermal load under load its behavior, electrical efficiency variations, and current-voltage fluctuations account for 30 The responses are analyzed within the same test cycle. Thus, the inverter (12) test, by removing the alternator (1) and battery (11) tests from being independent of each other and making them a single unit. An integrated validation process is established. 6 In summary, the system's operating principle is as follows: - The electric motor (2) is operated at the speed specified in the test scenario. - The motor shaft (3) starts to rotate steadily via bearings (4). - The pulley (6) on the motor shaft (3) is connected to the alternator (1) via the belt (5) It rotates the pulley. 5 - The alternator (1) is driven and produces electrical energy. - The generated electrical energy is directed to the batteries (11) charging scenario is created. - Thermal and electrical performance by simultaneously putting the inverter (12) under load. It is evaluated. 10 - Thanks to the simultaneous operation of all components, the alternator (1), battery (11) and Validation of the inverter (12) is carried out on a single platform. 20 30

Claims

7 REQUESTS 1- The invention relates to the alternator (1), battery (11) and inverter (12) used in vehicles. an alternator test that allows testing under load in a laboratory environment The table (10) system has the following features: - by providing driving force to the alternator (1) different operating speeds 5 at least one electric motor (2) that enables its creation, - mechanically the rotational motion produced by the electric motor (2) a motor shaft (3) that transmits and ensures the continuity of the system, - the motor shaft (3) rotates smoothly and stably with low friction by providing at least one bearing that reduces mechanical losses (4), 10 - by providing torque transfer between the motor shaft (3) and the alternator (1) Simulation of the alternator drive principle in vehicles in a laboratory environment consisting of at least one belt (5) and at least one pulley (6) that allows it to be made a transmission mechanism, - ensuring the alternator (1) operates in the correct position and alignment during the test period 15 by providing at least one that enables belt tension and vibration control. to the alternator mounting bracket (9), - fixing the electric motor (2) to the test table (10) and the drive axis to at least one engine front mounting bracket (7) which provides protection, - The motor shaft (3) and bearings (4) are mechanically placed on the test bench (10) 20 at least one bearing that increases system stability by ensuring it is secured. to the connecting bracket (8), - testing where all mechanical and electrical components are located enabling vibration damping and safe operation during the process to a test bench body (10), 25 - tested by charging with electrical energy produced by alternator (1). during which at least one realistic electrical load is created for the alternator (1) to the battery (11) - and by operating the alternator (1) and the battery (11) simultaneously under load at least one 30 that allows testing of its electrical and thermal behavior an alternator test bench characterized by having an inverter (12) (10) is the system.

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