Analysis of Cylindricity Error of High and Low Temperature Storage Tested Alternator Stators
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ght © 2020 KSAE/ 11818 pISSN 12299138/ eISSN 19763832
ANALYSIS OF CYLINDRICITY ERROR OF HIGH AND LOW TEMPERATURE STORAGE TESTED ALTERNATOR STATORS Gyula Varga* and Viktoria Ferencsik Institute of Manufacturing Science, University of Miskolc, Miskolc Egyetemváros 3515, Hungary (Received 7 May 2019; Revised 18 November 2019; Accepted 21 January 2020) ABSTRACTThis paper investigates the internal shape correctness of alternator stators occurring in high and low temperature storage tests. This kind of failure can affect the adequate operation of alternators since vibrations can occur during rotation of the other part of the alternator, the rotor. This error can reduce the efficiency of the alternator. The aim of this study is to examine the influence of different testing parameters, such as the temperature and the running time of the test, and whether or not the stator is equipped with a damping element. For the experiments we used the full factorial experimental design method. The measurement of the cylindricity of the specimens was done with a circular and position error measuring machine. From the measured data, special improvement ratios can be calculated in order to define the appropriate range of testing parameters that resulting greater deformity. A further aim is to compare the different cylindricity parameters and the features of theirs measured values. KEY WORDS : Alternator, Stator, Factorial Experimental Design, Climatic test, Shape correctness, 3D diagram
NOMENCLATURE
for propulsion, which in turn means that higher engine speed or greater throttle is necessary to achieve the desired acceleration in any given circumstance. Inappropriate operation of the alternator leads to further loss of performance; therefore, manufacturers consider this to be extremely important and employ different testing methods (Lee et al., 2001). The present study was undertaken to diagnose the failure problem of cylindricity of alternator stators that were tested with high and low temperature storage tests. The full factorial experimental design was used in this research, which is valid between the minimum and maximum values of the input parameters. In the present experiments the input parameters were: temperature of the test (T), test running time (t), and whether the stator was equipped with a damping element (DE).
T : temperature, oC t : time, h ρCYL : improvement ratio of cylindricity, % CYLtested : cylindricity deviation remaining after rapid temperature change test, m CYLset : cylindricity deviation remaining after setting the stator with brackets, m CYLp : peak-to-reference cylindricity deviation, µm CYLv : reference-to-valley cylindricity deviation, µm CYLt : peak-to-valley cylindricity deviation, µm CYLtt : cylinder taper, µm
SUBSCRIPTS
2. DESIGN FEATURES OF AUTOMOTIVE ALTERNATORS
x1, x2, x3: transformed parameters
1. INTRODUCTION
The main parts of a typical claw pole alternator are shown in Figure 1. An alternator is designed to maintain the state of charge of battery of a car while the car is being driven by
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