Brushless Alternator
This design is more efficient because there are no brushes to wear down or to arc at high altitudes. This generator consists of a pilot exciter, an exciter, and the main generator system. The need for brushes is eliminated by using an integral exciter with a rotating armature that has its AC output rectified for the main AC field, which is also of the rotating type. [Figure 12-324]
The pilot exciter is an 8 pole, 8,000 rpm, 533 cps, AC generator. The pilot exciter field is mounted on the main generator rotor shaft and is connected in series with the main generator field. The pilot exciter armature is mounted on the main generator stator. The AC output of the pilot exciter is supplied to the voltage regulator, where it is rectified and controlled, and is then impressed on the exciter field winding to furnish excitation for the generator.
The exciter is a small AC generator with its field mounted on the main generator stator and its three-phase armature mounted on the generator rotor shaft. Included in the exciter field are permanent magnets mounted on the main generator stator between the exciter poles.
The exciter field resistance is temperature compensated by a thermistor. This aids regulation by keeping a nearly constant resistance at the regulator output terminals. The exciter output is rectified and impressed on the main generator field and the pilot exciter field. The exciter stator has a stabilizing field, which is used to improve stability and to prevent voltage regulator over-corrections for changes in generator output voltage.
The AC generator shown in Figure 12-324 is a 6 pole, 8,000 rpm unit having a rating of 31.5 kilovoltamperes (kVA), 115⁄200 volts, 400 cps.
This generator is three-phase, 4 wire, wye connected with grounded neutrals. By using an integral AC exciter, the necessity for brushes within the generator has been eliminated. The AC output of the rotating exciter armature is fed directly into the three-phase, full-wave, rectifier bridge located inside the rotor shaft, which uses high-temperature silicon rectifiers. The DC output from the rectifier bridge is fed to the main AC generator rotating field.
Voltage regulation is accomplished by varying the strength of the AC exciter stationary fields. Polarity reversals of the AC generator are eliminated and radio noise is minimized by the absence of the brushes. A noise filter mounted on the alternator further reduces any existing radio noise. The rotating pole structure of the generator is laminated from steel punchings, containing all six poles and a connecting hub section. This provides optimum magnetic and mechanical properties.
Some alternators are cooled by circulating oil through steel tubes. The oil used for cooling is supplied from the constant speed drive assembly. Ports located in the flange connecting the generator and drive assemblies make oil flow between the constant speed drive and the generator possible.
Voltage is built up by using permanent magnet interpoles in the exciter stator. The permanent magnets assure a voltage buildup, precluding the necessity of field flashing. The rotor of the alternator may be removed without causing loss of the alternator’s residual magnetism.
Alternator Frequency
The frequency of the alternator voltage depends upon the speed of rotation of the rotor and the number of poles. The faster the speed, the higher the frequency; the lower the speed, the lower the frequency. The more poles on the rotor, the higher the frequency for a given speed. When a rotor has rotated through an angle so that two adjacent rotor poles (a north and a south pole) have passed one winding, the voltage induced in that winding has varied through one complete cycle. For a given frequency, the greater the number of pairs of poles, the lower the speed of rotation. A two-pole alternator rotates at twice the speed of a four-pole alternator for the same frequency of generated voltage. The frequency of the alternator in cycles per minute (cpm) is related to the number of poles and the speed, as expressed by the equation:
Where: P is the number of poles per phase
f is the frequency in cps
N is the rated speed in rpm
For example, a 2-pole, 3,600 rpm alternator has a frequency of: 
A 4-pole, 1,800 rpm alternator has the same frequency; a 6-pole, 500 rpm alternator has a frequency of:
A 12-pole, 4,000 rpm alternator has a frequency of:
Starter Generator
Many turbine-powered aircraft use a starter generator that acts like a starter during the start of the engine and when the engine is online it acts like a Generator. [Figure 12-325]
The main advantage of the starter generator is saving weight by eliminating a separate starter that is only used during the start. Initially used on small turboprops and light jets but large units are now installed on the B787 aircraft engines to power the main engines and power the electrical system.
Alternator Rating
The maximum current that can be supplied by an alternator depends upon the maximum heating loss (I2R power loss) that can be sustained in the armature and the maximum heating loss that can be sustained in the field. The armature current of an alternator varies with the load. This action is similar to that of A 12 pole, 4,000 rpm alternator has a frequency of DC generators. In AC generators, however, lagging power factor loads tend to demagnetize the field of an alternator, and terminal voltage is maintained only by increasing DC field current. For this reason, AC generators are usually rated according to kVA, power factor, phases, voltage, and frequency. One generator, for example, may be rated at 40 kVA, 208 volts, 400 cycles, three phase, at 75 percent power factor. The kVA indicates the apparent power. This is the kVA output, or the relationship between the current and voltage at which the generator is intended to operate. The power factor is the expression of the ratio between the apparent power (volt-amperes) and the true or effective power (watts). The number of phases is the number of independent voltages generated. Three-phase generators generate three voltages 120 electrical degrees apart.
Alternator Maintenance
Maintenance and inspection of alternator systems is similar to that of DC systems. Check the exciter brushes for wear and surfacing. On most large aircraft with two or four alternator systems, each power panel has three signal lights, one connected to each phase of the power bus, so the lamp lights when the panel power is on. The individual buses throughout the airplane can be checked by operating equipment from that particular bus. Consult the manufacturer’s instructions on operation of equipment for the method of testing each bus.
Alternator test stands are used for testing alternators and constant speed drives in a repair facility. They are capable of supplying power to constant speed drive units at input speeds varying from 2,400 rpm to 9,000 rpm.
A typical test stand motor uses 220/440 volt, 60 cycle, three-phase power. Blowers for ventilation, oil coolers, and necessary meters and switches are integral parts of the test stand. A load bank supplies test circuits. An AC motor generator set for ground testing is shown in Figure 12-326.
A typical, portable, AC electrical system test set is an analyzer, consisting of a multirange ohmmeter, a multirange combination AC DC voltmeter, an ammeter with a clip-on current transformer, a vibrating reed type frequency meter, and an unmounted continuity light.
A portable load bank unit furnishes a load similar to that on the airplane for testing alternators, either while mounted in the airplane or on the shop test stand. A complete unit consists of resistive and reactive loads controlled by selector switches and test meters mounted on a control panel. This load unit is compact and convenient, eliminating the difficulty of operating large loads on the airplane while testing and adjusting the alternators and control equipment.
Proper maintenance of an alternator requires that the unit be kept clean and that all electrical connections are tight and in good repair. If the alternator fails to build up voltage as designated by applicable manufacturer’s technical instructions, test the voltmeter first by checking the voltages of other alternators, or by checking the voltage in the suspected alternator with another voltmeter and comparing the results. If the voltmeter is satisfactory, check the wiring, the brushes, and the drive unit for faults. If this inspection fails to reveal the trouble, the exciter may have lost its residual magnetism. Residual magnetism is restored to the exciter by flashing the field. Follow the applicable manufacturer’s instructions when flashing the exciter field. If, after flashing the field, no voltage is indicated, replace the alternator, since it is probably faulty.
Clean the alternator exterior with an approved fluid; smooth a rough or pitted exciter commutator or slip ring with 000 sandpaper; then clean and polish with a clean, dry cloth. Check the brushes periodically for length and general condition. Consult the applicable manufacturer’s instructions on the specific alternator to obtain information on the correct brushes.
Regulation of Generator Voltage
Efficient operation of electrical equipment in an airplane depends on a constant voltage supply from the generator. Among the factors, which determine the voltage output of a generator, only one, the strength of the field current, can be conveniently controlled. To illustrate this control, refer to the diagram in Figure 12-327, showing a simple generator with a rheostat in the field circuit.
If the rheostat is set to increase the resistance in the field circuit, less current flows through the field winding and the strength of the magnetic field in which the armature rotates decreases. Consequently, the voltage output of the generator decreases. If the resistance in the field circuit is decreased with the rheostat, more current flows through the field windings, the magnetic field becomes stronger, and the generator produces a greater voltage.
Voltage Regulation with a Vibrating-Type Regulator
Refer to Figure 12-328.
With the generator running at normal speed and switch K open, the field rheostat is adjusted so that the terminal voltage is about 60 percent of normal. Solenoid S is weak and contact B is held closed by the spring. When K is closed, a short circuit is placed across the field rheostat. This action causes the field current to increase and the terminal voltage to rise.
When the terminal voltage rises above a certain critical value, the solenoid downward pull exceeds the spring tension and contact B opens, thus reinserting the field rheostat in the field circuit and reducing the field current and terminal voltage.
When the terminal voltage falls below a certain critical voltage, the solenoid armature contact B is closed again by the spring, the field rheostat is now shorted, and the terminal voltage starts to rise. The cycle repeats with a rapid, continuous action. Thus, an average voltage is maintained with or without load change.
The dashpot P provides smoother operation by acting as a damper to prevent hunting. The capacitor C across contact B eliminates sparking. Added load causes the field rheostat to be shorted for a longer period of time and, thus, the solenoid armature vibrates more slowly. If the load is reduced and the terminal voltage rises, the armature vibrates more rapidly and the regulator holds the terminal voltage to a steady value for any change in load, from no load to full load, on the generator.
Vibrating-type regulators cannot be used with generators, which require a high-field current, since the contacts pit or burn. Heavy-duty generator systems require a different type of regulator, such as the carbon pile voltage regulator.
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