ALTERNATOR IN CARS

How to ensure your alternator rating is correct for your car, including additional equipment & your driving routine.
1. Ensure your battery is fully charged;
2. Disconnect cable from Alternator + post (take care, the cable is live - if unsure, disconnect the Battery + terminal first, reconnect after! Insulate the cable terminal to prevent short circuit);
3. With respect to your electricity usage write down your worst prolonged driving condition, even if it happens but once a year (for instance driving for several hours at night, in hot weather, rain, pulling a trailer. This equals low beam, air cond in 'medium', fog lights, wipers, stereo, rear defogger, etc.. Less than, say, half-an-hour situations need not be considered);
4. Attach an ampmeter to the battery positive cable as shown on the picture (negative cable can also be used, if more convenient);
5. Start the engine, turn everything on you have written down under item 3 and hold the rpm on about 1500, or higher;
6. If they are powered by electric motors, wait for the radiator cooling fans to be turned on (or turn them on by bridging their relays);
7. Write down the highest reading on the ampmeter;
8. Turn everything off (ignition switch last);
9. Add 20% to the figure obtained under item 7 and THAT IS WHAT YOUR ALTERNATOR MINIMUM RATING* SHOULD BE! In most cases you'll discover that the rating of your alternator is well below that figure, and that's where most of the charging problems are hidden (for multiple batteries system calculation ref. item below);
* RATING = current output of the alternator shown on a label. Usually indicated as, for instance, 80A
10. When finished, reconnect your alternator (with the engine NOT running).
Take care - same as item 2!

MULTIPLE BATTERIES IN CARS

Connection as shown on the attached drawing.

If multiple batteries are required to power consumers used while the engine is not running (a fridge, TV set, etc.), the AH/RC of the battery (batteries) must be calculated so that the battery voltage does not drop much below 11 Volts before the engine needs to be started (for simplicity, and if possible, preference should be given to single battery with sufficient AH/RC).

With reference to ALTERNATOR RATING IN CARS above, 20% must be added to the alternator rating figure for every additional battery (or a battery with substantially higher AH/RC than standard).

BATTERY IN CARS

1. Batteries in most new cars are only about 50% good*, often less. The reason is self-discharge of standard lead-acid batteries and the long time it takes from manufacture to the Customer. Once discharged and kept discharged for a period of time the bateries do not accept full charge again;
* '50% good' means their capacity expressed in AH or RC is only 50%.
2. Replacement batteries are also only about 50% good, for the same reasons as above.

Invest in one of these tools, available from all auto shops, and see for yourself. it gives you a crude indication of the state of your battery; for more precise indication a controlled discharge test is needed.

Exceptions are lead-acid batteries that are kept dry and filled with acid & charged immediately prior to delivery/installation. Another exception are special batteries, for instance some of those with 'spiral' contructions; their cost, however, is usually several times the cost of the standard batteries.

CHARGING SYSTEM

Details to be advised.

EMERGENCY VEHICLES ELECTRICAL SYSTEM

Recently we have been asked to investigate electrical problems in a large fleet of emergency vehicles. These vehicles (some 12 different models) were basic cars - some brand new, some with some mileage already - fitted with additional computers, transceivers, search lights, warning lights, electrically powered medical equipment, etc.
# in about half of the fleet the alternators were found to be inadequate (ref. ALTERNATOR IN CARS in our blog);
# in all of the vehicles the batteries were faulty (ref. BATTERY IN CARS, or MULTIPLE BATTERIES IN CARS in our blog);
# in vehicles with dual batteries the two batteries were connected in a way that promoted premature failure of one of the batteries, leading to the subsequent failure of the remaining battery.
Some of these vehicles required a replacement battery (or batteries) every two weeks. Needless to say, the replacement batteries were also faulty (again, ref. BATTERY IN CARS in our blog).
The additional component's wiring & its termination was not done to the standards applicable to the wiring in the original vehicles, the workmanship was poor, which all contributed to a continuous litany of electrical problems.

ELECTRICAL SYSTEM DESIGN COST SAVING

Details to be advised.

TESTING OF ELECTRICAL SYSTEM IN HIGH VOLUME PRODUCTION VEHICLES

While designing electrical system for some of the vehicles listed in this blog it has been realised that the vehicles were entering full production without the electrical system being fully tested. As a rule, prior to start of full productions, a number of vehicles in various combinations are tested. These tests are designed to verify the mechanical properties of these vehicles; of necessity , the number of vehicles used in these tests seldom exceeds 100. The combinations are chosen under mechanical requirements guidelines. Electrical system, on he other hand, can have several thousand of different combinations! Some of the variations encountered in a standard passenger vehicle production run are listed on the attached chart (yet to be added!).
After having been involved in the design of the electrical system for more than a quarter of a century, our company has over that time developed a Method of Electrical System Testing which, when properly applied, ensures that all vehicles on entering full production, and beyond, are completely free of any electrical faults/problems/malfunctions, etc.

PASSENGER CARS ELECTRICAL SYSTEM (3)

TOYOTA CAMRY 2003
Design (partial) of the electrical system, for Australian and Middle Eastern markets.
Method of drafting-stage checking of electrical system developed.
Testing of the electrical system prior to volume production to ensure absence of electrical problems (initial version of our TESTING OF ELECTRICAL SYSTEM......., for more details ref. item above).

PASSENGER CARS ELECTRICAL SYSTEM (2)

TOYOTA CAMRY 1996
Design (partial) of the electrical system.
Testing of the electrical system prior to volume production to ensure absence of electrical problems (initial version of our TESTING OF ELECTRICAL SYSTEM......., ref. item above).

PASSENGER CARS ELECTRICAL SYSTEM (1)

Mitsubishi Diamante 1993
Official designation TR. Produced in Australia for export to the USA and Europe. Our brief had been to ensure that the vehicle is free of electrical problems, and that its electrical system complies with all applicable standards/regulations/requirements/etc.

GMC SIERRA 6.5L

A large fleet of emergency vehicles examined. All of these vehicles have been subsequently withdrawn from service.

Complaints: 1. overheating engines; 2. engines stopping at random intervals; 3. batteries failing.

Findings: 1. radiator intake opening clogged with emergency lights, sirens, etc.; 2. incorrect wiring arrangement around the Fuel Solenoid Module (ref. attached drawings);

3. batteries faulty when new, batteries incorrectly interconnected, batteries' inadequate capacity, crews unaware of vehicles' limitations.

Note.

1.Revisions proposed to the Module itself (removal of gasket, covers, etc.) are probably not important;

2.Findings not fully verified as the vehicles have been disposed of.

TRAILER ELECTRICAL SYSTEM

TRUCK WITH ONE, TWO, THREE OR FOUR TRAILERS.

Detailed drawings of electrical circuits available for all combinations.
Included are alternator ratings requirements, number of batteries required, battery cables arrangements, wire sizes requirements, suggested plugs, fuses, etc.
Free evaluation of your most troubling truck-trailer combinations (Melbourne, Australia, metropolitan area only, elsewhere travel expenses ex Melbourne required);
Rework of your truck/trailer can be arranged thru our company (Melbourne, Australia, metropolitan area only).
Fleet inquiries welcome.

TRUCK ELECTRICAL SYSTEM

In 1995-2000 we have designed electrical system for a new truck. During that time we have revised electrical system on a range of heavy trucks with diesel engines ranging in size between 8 & 20 litres. These trucks had a long history of electrical problems; with our revisions the problems have been reduced to zero. Also, we managed to reduce cost of the electrical system components in each of these truck (annual production about 1000) by $AU400 approx.
Free evaluation of your most troubling trucks (Melbourne, Australia, metropolitan area only, elsewhere travel expenses ex Melbourne required);
Rework of your truck can be arranged thru our company (Melbourne, Australia, metropolitan area only);
Fleet inquiries welcome.

ADI FLYER ELECTRICAL SYSTEM

An all-terrain multi-purpose vehicle, initially in military configuration.
Our company designed complete electrical circuit, all the wiring and some electrical /electronic components for this vehicle.

INDUSTRIAL ROBOTS ELECTRICAL SYSTEM

Design of electrical system, wiring, junction boxes, etc., for a range of industrial robots (some 100 off) used for assembly of passenger vehicles bodies, handling of a variety of components, etc..
Included in the contract was management of manufacture of all electrical components, their assembly, testing and subsequent commissioning at the various Customer's plant (mostly Ford Motor Company of Australia).
Photograph not available; shown is a sample of a drawing produced on one of our first computers.

LAWN MOWER PATENT

Energy saving Lawn Mower action.
After series of tests with a number of different blades' arrangement a Lawn Mower has been produced, and an Australian Patent has been successfuly applied for. Further tests proved that it was possible to cut a standard size lawn (20x20 metres approx.) using power from one 12 Volt / 15AH motocycle battery. Due to the economy crisis at the time (1987-1991) no investor could be found to enable further development, and the idea has remained on the back shelf ever since.

CENTRAL CONTROL MODULE

Designed and manufactured for the TD2000 Sports Car.
Features up to 12 essential control functions, such as Parking Lamps, Headlamps, Turn Signal Lamps, Stop Lamps, Reversing Lamps, Fuel Pump, Horn, Driving Lamps, etc. Provision for Burglar Alarm was optional.

TD2000 Sports Car

Also known as MGTD.
Several versions produced by a variety of manufacturers in Australia between the years 1985 and (approx.) 1990. First version used a 2000cc carburetted engine, later ones a 2000cc fuel injected engine.
Our company designed complete electrical circuit, all the wiring and some electrical /electronic components for all versions (ref. CENTRAL CONTROL MODULE).

ASTA NOMAD

Electrical system modification (U.S. Coastguard provisions added).

NISSAN PULSAR/HOLDEN ASTRA

NISSAN PULSAR/HOLDEN ASTRA 1987-89 MODELS.
Official designation AD44A and AD44B.
A range of passenger vehicles with 1800-2000 cc fuel injected engines.
Our company designed complete electrical circuit, 3 levels of Main Wiring harnesses, 3 levels of Body Harnesses and 2 levels of Instrument Harnesses.
Named the Australian manufactured vehicle "with the least number of electrical faults" in the 1992 survey by the Royal Automotive Club of Victoria.

THE BEGINNINGS

Prior to joining our company on either full-time, or as-required basis, our operators worked in the automotive industry as electrical engineers, design draftsmen or technicians. The number of vehicles for which the electrical system and its components have been designed by them include: GM Holden's HZ Kingswood, JB-JD Camira, WB Statesman, VK & VL Commodore; some operators used to work for a variety of automotive wiring harness manufacturers.