Alternator Load vs Fuel Economy.

Submitted: Sunday, Oct 09, 2005 at 21:40
ThreadID: 27127 Views:4238 Replies:8 FollowUps:15
This Thread has been Archived
This is somthing that I havn't really put a lot of thought into before, however my friend has just had the alternator replaced on his commodore as it was knackered (no charge) and he reckons his fuel economy has improved quite dramatically since fitting.

I have doubts about how well my alternator is running as it seems to be struggling a little of late, and with 200amp hours of batteries under the bonnet and all my crap running I wonder how much extra load that's putting onto the engine and weather it would be significant enought to noticbly reduce my fuel economy?

Anyone done any tests on this?
Back Expand Un-Read 0 Moderator

Reply By: GUPatrol - Sunday, Oct 09, 2005 at 22:04

Sunday, Oct 09, 2005 at 22:04
Jeff,
A 50amp alternator at full load takes aproximately 1hp of power, modern alternators are between 80amp to 100 amp but none work on full blast ever unless you are running lots of electrical devices all at once (easy to calculate).

THe only thing where fuel economy can be attributed to a fault in the electrical circuit (ie: alternator) is the changes the ECU makes to the fuel delivery and loading to compesate for voltage drops etc, but that would not be noticeable.
AnswerID: 133835

Follow Up By: Member - Jeff M (WA) - Sunday, Oct 09, 2005 at 22:33

Sunday, Oct 09, 2005 at 22:33
So I could potoentially save 1hp or so if it was running in A1 condition rather than running flat stick all the time. Probally not really worth it. :-)

Thanks.
0
FollowupID: 387974

Reply By: Mainey (WA) - Sunday, Oct 09, 2005 at 22:21

Sunday, Oct 09, 2005 at 22:21
I think the motors going to spin the alternator and if electricity is produced or not the dam things still going to be spun by the engine, it's not like an airconditioner where the aircon only drives the aircon pump when the aircon is actually engaged and the aircon clutch is connected/disconnected, the alternator is allways engaged and also spinning.
If it produces power is not relevant to the force applied to make it actually spin.

I'm sure it takes no more engine power to spin an alternator that IS producing power to one thats NOT producing power, how does it make the alternator harder to spin if it's producing power.
The power is produced in the alternature windings and then sent to the REGULATOR, so power is being produced even if it is not available to the battery, unless the alternator is stuffed and then the light on the dash is on...
AnswerID: 133837

Follow Up By: Member - Jeff M (WA) - Sunday, Oct 09, 2005 at 22:32

Sunday, Oct 09, 2005 at 22:32
No Mainy, that's not correct. A generator will become harder to turn the more load you put on it. ie You don't pull start a genny with full load plugged into it as it would be much harder to start than if the load is switched off first. (that's why it's called a load).

My question was more about the exact amount of load from an alternator running nothing to an alternator working flat chat with maxium load. Apparantly from the reply above about 2hp which is not a massive amount. I'd say mine is working flat out all the time at the mo as the voltage is rarely getting up to 14v, it's sitting around 13.5v-13.7v which is too low IMHO. I was wondering if reconning the alternator would make it more efficiant there by saving a small amount of fuel. I guess saving 1hp is not going to make much difference to the surf's economy though...
0
FollowupID: 387973

Follow Up By: Mainey (WA) - Monday, Oct 10, 2005 at 10:50

Monday, Oct 10, 2005 at 10:50
I won't "argu" with a fellow (WA) but... I find it really hard to understand how an alternator becomes "harder to spin" by the engine, and cause the engine to use more fuel etc in the process, simply because it's producing 12v electricity, the alternator is going to be spun by the engine, via a 'fanbelt' generally, at all times when the engine is running, the only difference will be if it's producing power, (if the battery is totally fully charged, no power is going from the regulator, but it's still produced by alternator) and as there is no actual physical touching items that will slow down the alternator only the 12v electricity being produced, other the bearings and seals within the alternator nothing else causes any friction to use more power by the engine, well I may be wrong... but it would have to be the actual '12v electricity' being produced and sent to the regulator that slows the alternator and therefore also the engine causing it to use more fuel, and I don't think that's feasable :-)
For the alternator to use more fuel when it IS working it would have to be something that is not a "constant drag" on the alternator, ie something that turns on and off, and as the mechanicals of the alternator (bearings, seals etc) are a constant force, only the actual 12v electricity changes.. ? ? ?
0
FollowupID: 388020

Follow Up By: Member - Jeff M (WA) - Monday, Oct 10, 2005 at 11:46

Monday, Oct 10, 2005 at 11:46
I can understand your confusin, but just for your own interest, perhaps crag a small 12v motor from dick smith for a couple of dollar and a small light globe. Spind the motor with your finger with the light globe dsiconeccted, then try again with the light on, you'll notice that because it is trying to now power the light glove it will be harder to turn. You don't get free energy. Spinning the motor with no load will surely produce 12v, but at no amps it's not creating and load.
0
FollowupID: 388029

Follow Up By: Tim HJ61 (WA) - Monday, Oct 10, 2005 at 11:50

Monday, Oct 10, 2005 at 11:50
Hi Mainey,

There MUST be a load put the engine when the alternator is producing high amps otherwise we'd be able to get free electricity. eg high capacity generators needs high power engines, or big fan blades on a wind farm, or big turbines on a hydro system.

At an apparently sensible web page, they state
"A 200-W electrical load accounts for about 0.4 km/L in the FTP 75 cycle test"

It's something to do with magnetism increasing with current - therefore there doesn't need to be anything touching to increase the load on the pulley.

I feel a bit like the advert on TV where the Dad is trying to explain why they built the great wall of China - 'to keep the rabbits out son' ...

Mainey, there's a load demand on the engine because of electro-magnetic force, yep, that's what it is - electro-magnetic force.

Tim
0
FollowupID: 388030

Reply By: Tim HJ61 (WA) - Sunday, Oct 09, 2005 at 22:49

Sunday, Oct 09, 2005 at 22:49
Jeff,

Maybe it's your regulator that needs a tweak to up your preferred voltage, not an alternator issue at all.

Alternators have a whistle about them when working really hard. If it is working flat out, all that power's gotta being going somewhere. Are you always running your batteries down with accessories after the engine is turned off? If not, where is the power going?

I'm thinking if your voltage is down, I'd be checking your regulator and adjusting it if you can. Then keeping a check on the batteries to make sure you're not overcharging them.

Tim
AnswerID: 133839

Follow Up By: Member - Jeff M (WA) - Sunday, Oct 09, 2005 at 22:57

Sunday, Oct 09, 2005 at 22:57
The regulator is built into the surf's alternator. Yeah there is gear on in the car when not in use but not much, batteries will discharge a little by themselves anyway and their is also parasitic loads from alarms, radios, ECU memory etc.
The voltage is lower now than it used to be and nothing else has changed.
The bateries are both less than 12 months old and are calcium-caclium so they deffinatally are not getting over charged even at 14.1 as they can be charged as high as 14.8v and I only do city driving normally during the week, short runs.
To over charge 200 amp hours od batteries around town would be pretty hard to do unless your regulator was completley kuput. The problem apparent especially with headlights on and wipers or indicators, air con condesnor fan, inside vent fan etc etc.
0
FollowupID: 387983

Follow Up By: Member - Jeff M (WA) - Sunday, Oct 09, 2005 at 22:59

Sunday, Oct 09, 2005 at 22:59
If the regulator was the issue they would be consisantly low, however the voltage drops lower when large accessories (like lights etc) are switched on which leads me to think that the alternator can't cope anymore not that the regulator is putting out too lower voltage.
0
FollowupID: 387984

Follow Up By: Tim HJ61 (WA) - Sunday, Oct 09, 2005 at 23:02

Sunday, Oct 09, 2005 at 23:02
Might have a sick diode or three. Worthwhile getting it checked.

Tim
0
FollowupID: 387985

Follow Up By: Member - Jeff M (WA) - Sunday, Oct 09, 2005 at 23:10

Sunday, Oct 09, 2005 at 23:10
It's going to be a mongral either way, the bloody thing is in a PITA spot right down the bottom under the air con compressor and you haved to take the aux bat out and the bash plate off just to access the adjuster bolt. Oh well, if it's not the regulator I might see how much to upgrade it from 70amp to 90 or whatever they can go up to when they re-coil it. Make it worth my while. :-)
0
FollowupID: 387988

Follow Up By: Tim HJ61 (WA) - Monday, Oct 10, 2005 at 10:11

Monday, Oct 10, 2005 at 10:11
Hi Jeff,

I wouldn't muck around with a 20A increase if I was going to get my alternator done up. Add an extra 50A or something really chunky to make it worthwhile.

I was in the fortunate position of having a 24v 30A alternator that could simply have a 12V 60A stator installed during the rebuild, so now it produces 24v at 60A - equiv of 120A at 12v. Vroom Vroom.

Other things Drive In Electrics in Wangara suggested to me was to run a new cable direct from the alternator to the battery, as there was around half a volt loss between alternator output point and battery. And as others have said, checking earthing and positive connections will help. Check the earth strap from motor to chassis too.

Tim
0
FollowupID: 388017

Follow Up By: Damian007 - Friday, Oct 14, 2005 at 07:39

Friday, Oct 14, 2005 at 07:39
To Tim HJ61,
I would recheck that statement of yours about the Stator being changed to deliver more current..
Being an Auto Electrician, I would suggest you actually get a proper reading on your Alternatoir Output using a good quality Ammeter..Check it under full load and see what voltage your actually maintaining and at what current..Thre's a reason why you can't just use a 12Volt 60 amp Stator to produce 24v..

The reason that an Alternator whistles while charging is because of the Rotor cutting through the Magnetic Flux of the Stator..The more current being drawn from the alternator, The more magnetic flux is generated..

One other thing while on this discussion..Anyone proposing to do an alternator swap on a Diesel has another worry. Most Diesesl have a Vacuum pump on the Back..New Alternators are pretty expensive with a Vacuum pump..
0
FollowupID: 388608

Follow Up By: Member - Jeff M (WA) - Friday, Oct 14, 2005 at 11:05

Friday, Oct 14, 2005 at 11:05
Nah, the vacume pump on the 1KZ-TE is seperate to the alternator on the otherside of the motor. I know this because it's been weeping oil from the seal to the motor for about 2 years now and I just havn't been assed to do anything about it... ;-)
0
FollowupID: 388641

Follow Up By: Tim HJ61 (WA) - Friday, Oct 14, 2005 at 11:26

Friday, Oct 14, 2005 at 11:26
Hi Damian007,

::::Thre's a reason why you can't just use a 12Volt 60 amp Stator to produce 24v..

I acknowledge your quals and experience without issue. Pleased to have a professional input.

The Auto Electrician that did up my alternator told me he had replaced the brushes, bearings of my alternator as part of a refit to try to boost charge. He also exchanged the stator for one out of a 12v unit as it produces the same Amps as it does in it's original 12v home, but due to [I'm guessing here] the other components of the alternator, the alternator still produces 24v. So now it's producing 60A at 24V, or approx, as measured on his bench test before reinstalling it.

Honestly, I don't even know which part of the alternator is, or what it does, I'm just repeating what I was told. I understand bits, just not the whole detail.

The alternator was done up around 8 months ago and is still working properly. It can run 6 x 100 w lights, plus charge an aux battery, plus all my fans, gadgets all turned on at the same time whilst maintaining 28.5v so I'm happy.

Tim
0
FollowupID: 388643

Reply By: Member - Jerry C (WA) - Sunday, Oct 09, 2005 at 23:26

Sunday, Oct 09, 2005 at 23:26
Jeff,
Have a look at the plate on the alternator, it may give the Ampere rating. An alternator will try and supply the load asked of it, so if you run it continuously at full load it will overheat and probably die and of course the output voltage will drop due to the internal series resistance of the alternator. If you have an amp meter put it in the output lead of the alternator and see what it reads but be prepared for a reading of 80 to 100 amps. It may be safer to take it to the Auto Elect.

Cheers

Jerry
AnswerID: 133842

Reply By: P.G. (Tas) - Monday, Oct 10, 2005 at 07:37

Monday, Oct 10, 2005 at 07:37
G'day Jeff, here's my 2 cents worth. Disconnect both batteries and fully charge them on a good battery charger. When you reconnect them, check your voltage then.

If it goes back to 14.1+volts, then things are fine and your truck just needs a few more good runs. If it stays the same as it is now, then look a little further.

Just a little point, how reliable/accurate is the volt meter you are using now and is it the same one you have been using all along?

Hope this helps, Cheers
AnswerID: 133857

Follow Up By: P.G. (Tas) - Monday, Oct 10, 2005 at 07:39

Monday, Oct 10, 2005 at 07:39
BTW, don't forget to make sure all your battery terminals are spotlessly clean, on the batteries and alternator/earth connections. That can make a HUGE difference!
0
FollowupID: 388004

Follow Up By: Member - Jeff M (WA) - Monday, Oct 10, 2005 at 11:43

Monday, Oct 10, 2005 at 11:43
Yeah I always clean all the battery connections every 5k when I service it, but there is a lot of mud and crap under there, may be worth a look. There is an earth connection to the chasis from both batteries, I'll check those too. The volt meter is a cheap POS but it has always read the same as my good multimeter, maybe I should check it again too. I thought the same thing about the batteries not being fully charged and gave them a go on the 3 stage on Friday, that's why I was concerned, because it was still a little low...
0
FollowupID: 388028

Reply By: Member - Geoff M (Newcastle) - Monday, Oct 10, 2005 at 10:53

Monday, Oct 10, 2005 at 10:53
Hello Jeff,
I'm going to delve into the dim distant recesses of my electrical theory here, so we'll see what comes out,
1 hp = 780 Watts, approximately.

Therefore, 100 Amps at 14.5 Volts would be,
100 x 14.5 = 1450 Watts

It would equal roughly,
1450 / 780 = 1.86 Hp, call it 2 Hp for mechanical friction, bearings, belts etc and we'd be close.

Take the roof rack off and wind up the windows for a bigger saving,

Geoff.
Geoff,

Grey hair is hereditary, you get it from children. Baldness is caused by watching the Wallabies.

Lifetime Member
My Profile  My Blog  Send Message

AnswerID: 133891

Reply By: Barry Crocker - Wednesday, Oct 12, 2005 at 14:56

Wednesday, Oct 12, 2005 at 14:56
Mainey, every action has an equal and opposite reaction, in this case more load on the alternator creates a bigger "back" emf opposite to the flow to all the gear being run which in turn loads up the donk just that little bit.....
AnswerID: 134302

Reply By: Member - Geoff M (Newcastle) - Wednesday, Oct 12, 2005 at 20:46

Wednesday, Oct 12, 2005 at 20:46
Hello Crew,
The way an alternator works is,
The bit that spins is called a rotor and has a pair of brass collars on it called slip rings. There is a coil wound into the rotor called the excitation fields, the wire ends of this coil are connected to the slip rings.
Carbon brushes run on the pair of slip rings and have a DC voltage applied to them.

The outer stationary part is known as the stator. It's the part of the alternator that outputs the current and voltage to charge our batteries and run the vehicle. The stator actually produces an AC or Alternating Current and this output is fed throught the diodes to rectify it into a DC voltage.

When we apply a load to our alternator the output voltage actually drops. This is where the regulator comes into the picture. It increases the current flow through the excitation fields via the carbon brushes to bring the output voltage back up to the required value. As the load on the output increases the regulator increases the excitation current until the maximum rated excitation current is reached. At about this point the alternator is producing its maximum output current too.

As the load and excitation increase, the magnetic field strength (flux density) is increasing in proportion to the current flow through the excitation fields. All this increasing magnetic field strength requires increasing levels of power to drive it.

Hence, as load on the alternator increases the power required to drive it increases.

The alternators in our power stations work in exactly the same way, except they don't have diode packs on the output. They transmit the AC output to our homes.

I've seen diesel engines stall at full load and speed on ships when someone has done something silly with the power system. This happens because the alternator has required more power than the diesel is capable of supplying. These installations will output anything up to 2,000 Amps per phase.

Hope this helps,

Geoff.
Geoff,

Grey hair is hereditary, you get it from children. Baldness is caused by watching the Wallabies.

Lifetime Member
My Profile  My Blog  Send Message

AnswerID: 134365

Sponsored Links

Popular Products (9)