Voltage regulator of a motor vehicle alternator, regulator brush-holder, and corresponding alternators

Abstract

The invention relates to a voltage regulator (43) for a motor vehicle alternator (44). The device comprises a control module (I) for controlling an excitation current (lexc) in an excitation winding (3) of the alternator (44) according to a difference (5) between a setpoint voltage (DO) and a control voltage (Dbat) of an on-board network (9). The on-board network (9) of the vehicle is powered by a battery (10) to which the alternator (44) is connected. According to the invention, the voltage regulator (43) further comprises a safety module (30) that monitors the control voltage (Ubat) and which is separate from the control module (I). In a particular embodiment, the control module (I) and the safety module (30) are connected electrically by external bonding interconnections.

Claims

1. Voltage regulator (1, 30, 39) of a motor vehicle alternator (2, 44) of the type comprising a regulation module (1, 39) which can control an excitation current (lexc) in an excitation winding (3) of said alternator (2, 44), according to a difference (5) between a set voltage (U0) and a regulation voltage (Ubat) of an on-board network (9) of said vehicle supplied by a battery (10) to which said alternator (2, 44) is connected, said regulation module (1, 39) comprising: a first earthing terminal (22) which is designed to be connected to an earth (21) of said on-board network (9); a first supply terminal (25) which is designed to be connected to a positive line (24) of said on-board network (9); a first excitation terminal (27) which is designed to be connected to said excitation winding (3); a measurement terminal (25, 40) which is designed to measure said regulation voltage (Ubat); and comprising: a voltage divider bridge (13), which is connected firstly to said measurement terminal (25, 40) and secondly to said first earthing terminal (22); a subtracter (14) which is connected at its input to said set voltage (U0), and to a midpoint of said voltage divider bridge (13); a regulation loop (12) which is connected at its input to said subtracter (14), and controls at its output a first semiconductor switch (16) which is connected between said first supply terminal (25) and said first excitation terminal (27); a first free wheel diode (17) which is connected between said first excitation terminal (17) and said first earthing terminal (22); wherein it also comprises a safety module (30) which carries out a function of monitoring of said regulation voltage (Ubat), which module is distinct from said regulation module (1, 39).

2. Voltage regulator (1, 30) of a motor vehicle alternator (44) according to claim 1, wherein said measurement terminal (25) is combined with said first supply terminal (25), and wherein said safety module (30) comprises: a second supply terminal (34) which is designed to be connected to said positive line (24); a second earthing terminal (35) which is designed to be connected to said earth (21); a second excitation terminal (32) which is connected to said first excitation terminal (27); a third excitation terminal (33) which is designed to be connected to said excitation winding (3); and wherein said safety module (30) comprises: a second semiconductor switch (31) which is connected in series to said excitation winding (3), between said second and third excitation terminals (32, 33); a second free wheel diode (37) which is connected between said third excitation terminal (33) and said second earthing terminal (35); a control circuit (36) which commands a blocked state of said second semiconductor switch (31) in the event of detection of an excess voltage on said second supply terminal (34) relative to said second earthing terminal (35), and commands re-establishment of an on state in the absence of said excess voltage, according to a predetermined strategy.

3. Voltage regulator (1, 30) of a motor vehicle alternator (44) according to claim 2, wherein said safety module (30) comprises standby and wake-up modes which are dependent on a variation of an excitation voltage on said second excitation terminal (32).

4. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 2.

5. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 3.

6. Voltage regulator (1, 30) of a motor vehicle alternator (44) according to claim 1, wherein said measurement terminal (25) is combined with said first supply terminal (25), and wherein said safety module (30) comprises: a second supply terminal (34) which is designed to be connected to said positive line (24); a second earthing terminal (35) which is connected to said first supply terminal (25); a third earthing terminal (38) which is designed to be connected to said (21) earth; and wherein said safety module (30) comprises: a second semiconductor switch (31) which is connected in series to said regulation module (1) between said second supply terminal (34) and said second earthing terminal (35); a control circuit (12) which commands a blocked state of said second semiconductor switch (31) in the event of detection of an excess voltage on said second supply terminal (34) relative to said third earthing terminal (38), and commands re-establishment of an on state in the absence of said excess voltage, according to a predetermined strategy.

7. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 6.

8. Voltage regulator (30, 39) of a motor vehicle alternator (44) according to claim 1, wherein said measurement terminal (40) is designed to be connected to said positive line (24), and wherein said safety module (30) comprises: a second supply terminal (34) which is designed to be connected to said positive line (24); a second earthing terminal (35) which is connected to said first supply terminal (25); a third earthing terminal (38) which is designed to be connected to said earth (21); and wherein said safety module (30) comprises: a second semiconductor switch (31) which is connected in series to said regulation module (39) between said second supply terminal (34) and said second earthing terminal (35); a control circuit (36) which commands a blocked state of said second semiconductor switch (31) in the event of detection of an excess voltage on said second supply terminal (34) relative to said third earthing terminal (38), and commands re-establishment of an on state in the absence of said excess voltage, according to a predetermined strategy.

9. Voltage regulator (30, 39) of a motor vehicle alternator (44) according to claim 8, wherein said regulation module (39) additionally comprises a first monitoring device (41) which controls said first semiconductor switch (16) in a first open state when a first differential voltage (V1) between said first supply terminal (25) and said measurement terminal (40) is greater than a first predetermined threshold.

10. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 9.

11. Voltage regulator (30, 39) of a motor vehicle alternator (44) according to claim 9, wherein said regulation module (39) additionally comprises a second monitoring device (42) which controls said first semiconductor switch (16) in a second open state when a second differential voltage (V2) between said measurement terminal (40) and said first supply terminal (25) is greater than a second predetermined threshold.

12. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 11.

13. Voltage regulator (30, 39) of a motor vehicle alternator (44) according to claim 11, wherein said first and second monitoring devices (41, 42) send respectively a first or second alarm (A1, A2) to a dashboard of said vehicle in the event, respectively, of breaking of a connection between said measurement terminal (40) and said positive line (24) or a failure of said second semiconductor switch (31).

14. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 13.

15. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 8.

16. Regulator brush-holder (18, 43) of a motor vehicle alternator (2) comprising a voltage regulator (1, 30, 39) according to claim 1.

17. Regulator brush-holder (43) of a motor vehicle alternator (44) according to claim 16, wherein said regulation module (1, 39) and said safety module (30) are connected electrically by external interconnections of the bonding type.

18. Regulator brush-holder (43) of a motor vehicle alternator (44) according to claim 17, wherein said regulation module (1, 39) and said safety module (30) are also connected electrically by other external interconnections of the bonding type to a circuit of tracks which is connected, firstly to brushes (19, 20) which can ensure an electrical connection to said excitation winding (3), and secondly, to a first screw (28) which forms a positive terminal of said alternator (44), and to a second screw (29) which forms a negative terminal of said alternator (44).

19. Motor vehicle alternator (2, 44), comprising a regulator brush-holder (43) according to claim 16.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an overview of a voltage regulator for an alternator known in the prior art.

(2) FIG. 2 illustrates the development of the regulation voltage according to the output for the regulator shown in FIG. 1.

(3) FIG. 3A is an overview of a voltage regulator for an alternator equipped with a safety module according to a first embodiment of the invention.

(4) FIGS. 3B and 3C are overviews of a voltage regulator for an alternator equipped with a safety module according to first and second variants of the first embodiment in FIG. 3A.

(5) FIG. 4 is an overview of a voltage regulator for an alternator with a safety module according to the second embodiment of the invention.

(6) FIG. 5 illustrates the development of the regulation voltage according to the output for the regulator shown in FIG. 4.

(7) FIG. 6 is an overview of a voltage regulator for an alternator with a safety module according to a variant of the second embodiment of the invention shown in FIG. 4.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

(8) A diagram of a voltage regulator 1 of the type to which the invention relates is represented in FIG. 1.

(9) This is a voltage regulator 1 for an alternator 2 with excitation for an application in a motor vehicle.

(10) This voltage regulator 1 is of the single-chip type, i.e. a regulation module 1 produced in the form of an ASIC contains all the electronic components necessary to control the excitation current lexc which circulates in the excitation winding 3 of a rotor 4 of the alternator 2 according to a difference 5 between a set voltage U0 and the regulation voltage Ubat supplied by phases 6 of the stator windings 7 of the alternator 2, after rectification 8 on the on-board network 9, to which the battery 10 of the vehicle and various charges 11 are connected.

(11) These electronic components are: a regulation loop 12; a voltage divider bridge 13 for adaptation of the regulation voltage Ubat to the voltage level required by the regulation loop 12; a subtracter 14 which generates the difference between the set voltage U0 stored 15 and the regulation voltage Ubat; a first semiconductor switch 16 of the MOSFET type which controls the excitation current lexc commanded by a pulse width modulated signal (MLI), with a duty cycle which is variable according to a result 5 of the subtracter 14, generated by the regulation loop 12; a first free wheel diode 17, in which the demagnetising current of the rotor 4 circulates when the first semiconductor switch 16 is open.

(12) Mostly, this type of single-chip regulator is integrated in a brush-holder 18 which comprises receptacles to receive brushes 19, 20, thus ensuring an electrical connection with the excitation winding 3 of the rotor 4 by means of a rotary collector.

(13) The brush-holder 18 comprises a circuit of tracks (in thick lines in FIG. 1) which makes it possible to connect the regulation module 1: to an earth 21 of the on-board network 9, by means of a first earthing terminal 22 by means of a negative regulation plug 23; to a positive line 24 of the on-board network 9, by means of a first supply terminal 25 by means of a positive regulation plug 26; to one of the brushes 19 by means of a first excitation terminal 27, with the other brush 20 being connected to the negative regulation plug 23.

(14) The positive regulation plug 26 and the negative regulation plug 23 of the brush-holder 18 are connected respectively by means of wired connections to a first screw 28 which generally forms a positive terminal B+A of the alternator 2, and to a second screw 29 which forms a negative terminal of the alternator 2, generally the earth.

(15) The first supply terminal 25 is also the measurement terminal from which the regulation voltage Ubat is collected by means of the voltage divider bridge 13. As a result of the wired connections between the brush-holder 18 and the alternator 2, a voltage at the terminals of the regulator 1 and the regulation voltage Ubat are identical.

(16) Thus, the regulation voltage Ubat according to the charge of the alternator 2 measured between the screw B+A 28 and the earthing screw 29 of the alternator 2 is very close to the set voltage U0 (for example 14V), depending on the output I of the alternator 2, as shown clearly in FIG. 2.

(17) However, this voltage regulator 1, shown in FIG. 1, has a disadvantage, since in the event of failure of the regulation module 1 (for example when the first semiconductor switch 16 remains blocked in the on state), the rotor 4 is supplied permanently via the first supply terminal 25 and the first excitation terminal 27.

(18) The regulation function is no longer ensured in this case, and an excess voltage is generated on the on-board network 9.

(19) In order to prevent this excess voltage on the on-board network 9 in the event of failure of an electronic component 16 of the voltage regulator 1, it is then necessary to implement a security mechanism using a second module which is separate from the regulation module 1, and carries out a function of monitoring of the regulation voltage Ubat of the on-board network 9 of the vehicle by the alternator 2.

(20) FIG. 3A shows schematically an alternator 2, 44 comprising a regulator brush-holder 18, 43 incorporating a voltage regulator 1 and a safety module 30 corresponding to a first embodiment of the invention, which eliminates the aforementioned disadvantage.

(21) In this first embodiment, a safety module 30 is interposed between the excitation winding 3 and a regulation module 1 which is identical to that of the known voltage regulator shown in FIG. 1.

(22) This safety module 30 comprises a second semiconductor switch 31 of the MOSFET transistor type which is connected in series to the excitation winding 3 at the output of the regulation module 1.

(23) This safety module 30 comprises a second excitation terminal 32 which is connected to the first excitation terminal 27 of the regulation module 1, and a third excitation terminal 33 which is designed to be connected to the brush 19 of the excitation winding 3.

(24) It is supplied between the second supply terminal 34 which is designed to be connected to the positive line 24 of the on-board network 9, and a second earthing terminal 35 which is designed to be connected to the earth 21.

(25) The second semiconductor switch 31 is connected between these second and third excitation terminals 32, 33, such as to cut off the excitation current lexc when a control circuit 36 detects an excess voltage on the second supply terminal 34 relative to the second earthing terminal 35.

(26) A second free wheel diode 37 is connected between the third excitation terminal 33 and the second earthing terminal 35, such as to make the demagnetising current of the rotor 4 circulate when the second semiconductor switch 31 is blocked.

(27) In the case of operation without failure of the voltage regulator 1, 30, the second semiconductor switch 31 remains in the on state; the current which magnetises the rotor 4, obtained from the battery 10, circulates via the first semiconductor switch 16, then the second 31.

(28) When the first semiconductor switch 16 is blocked during the low states of the pulse width modulated signal of the regulation loop 12, the first and second free wheel diodes 17, 37 allow the demagnetisation current to circulate.

(29) In the case of failure of the voltage regulator 1, 30, the first semiconductor switch 16 can remain switched in the on state (example of a possible failure mode).

(30) The safety module 30 then detects an excess voltage on the on-board network 9, and cuts off the excitation current lexc whilst blocking the second semiconductor switch 31.

(31) The demagnetisation is then carried out by the second free wheel diode 37.

(32) A strategy of cut-off of the excitation current lexc and re-engagement of this excitation current lexc is implemented by the safety module 30 according to a predetermined control.

(33) A standby mode of the safety module 30 can be based on reading an activity of the pulse width modulated signal.

(34) If activity of the pulse width modulated signal exists (detection of variation of an excitation voltage on the second excitation terminal 32), then the safety module 30 is positioned in wake-up mode. The safety module 30 is then immediately functional, and does not require an additional control wire to control the standby and wake-up modes.

(35) If no activity of the pulse width modulated signal is detected, and after a predetermined confirmation time, the safety module 30 can be placed in the standby mode (low consumption of current by the battery 10).

(36) FIGS. 3B and 3C show schematically an alternator 2, 44 comprising a regulator brush-holder 18, 43 incorporating a voltage regulator 1 and a safety module 30, 30, corresponding to 1.sup.st and second variants of the first embodiment of the invention in FIG. 3A.

(37) In these variants, the excitation winding 3 is fitted between two branches of an architecture of the type of a bridge in the form of an H.

(38) In the first variant in FIG. 3B, a first branch of this bridge in the form of an H comprises the first semiconductor switch 16 and the first free wheel diode D1, 17 of the voltage regulator 1. A second branch of this bridge in the form of an H comprises the second semiconductor switch 31 and a second free wheel diode D2, 37 of the safety module 30. The second semiconductor switch 31 is in this case connected according to a so-called low-side fitting between the earthing terminal 35 and an excitation terminal 33. The excitation terminal 33 is situated at a midpoint of the second branch. The free wheel diode D2 is connected between the excitation terminal 33 and the supply terminal 34. The two ends of the excitation winding 3 are connected respectively to the excitation terminals 27 and 33 by means of the brushes 19 and 20 respectively. With the exception of the demagnetisation obtained by means of the free wheel diode D1, D2, and which will not be described in detail here, the operation of the safety module 30 remains globally similar to that of the safety module 30.

(39) The second variant, in FIG. 3C, comprises a safety module 30. This second variant differs from the first variant in FIG. 3B in that the free wheel diodes D1, 17, and D2, 37 are eliminated and replaced by a single free wheel diode D2, 37. This free wheel diode D2 is fitted in parallel with the excitation winding 3, between the excitation terminals 27 and 33. With the exception of the demagnetisation obtained by means of the free wheel diode D2, and which will not be described in detail here, the operation of the safety module 30 remains globally similar to that of the safety modules 30 and 30.

(40) FIG. 4 shows schematically an alternator 2, 44 comprising a regulator brush-holder incorporating a voltage regulator 1, 30 in a second embodiment of the invention.

(41) In this second embodiment, a safety module 30 is placed in series in the positive line 24 of the on-board network 9, in order to supply a regulation module 1 which is identical to that of the known voltage regulator shown in FIG. 1.

(42) In this case, the safety module 30 comprises a second semiconductor switch 31 of the MOSFET transistor type connected between the second supply terminal 34, which is connected to the positive line 24, and a second earthing terminal 35, which is connected to the first supply terminal 25 of the regulation module 1.

(43) The second semiconductor switch 31 cuts off the excitation current lexc supplied by the on-board network 9 via the first semiconductor switch 16, when the control circuit 36 detects an excess voltage on the second supply terminal 34, relative to a third earthing terminal 38, which is designed to be connected to the earth 21.

(44) Since the regulation module 1 is not modified, a measurement Ureg of the regulation voltage Ubat is carried out by the voltage divider bridge 13 after the safety module 30, on the first supply terminal 25, relative to the first earthing terminal 22.

(45) In these conditions, the regulation voltage Ubat is increased for a given set voltage U0 because of the series resistance of the second semiconductor switch 31.

(46) For example, for an excitation current lexc of 5 A and a resistance in the on state of 0.1, the regulation voltage Ubat is increased by V=0.5V. For a set voltage U0 of 14V, the regulation voltage Ubat on the on-board network 9 is 14.5V.

(47) Thus, as shown clearly in FIG. 5, the regulation voltage Ubat according to the charge increases according to the current output I.

(48) If the failure of the second semiconductor switch 31 is of the resistive type, the regulation voltage Ubat increases considerably.

(49) For example, for an excitation current lexc of 5 A and a series resistance of the second defective semiconductor switch 31 of approximately 1, the regulation voltage Ubat is increased by V=5V.

(50) A variant of this second embodiment of the invention makes it possible to correct these errors of the regulation loop 12 by using a modified regulation module 39, as shown in FIG. 6.

(51) In the modified regulation module 39, the measurement terminal 40 to which the voltage divider bridge 13 is connected is no longer combined with the first supply terminal 25.

(52) This measurement terminal 40 is designed to be connected directly to the positive line 24, whereas the first supply terminal 25 is connected to this positive line 24 via the second semiconductor switch 31.

(53) This variant makes it possible to measure the regulation voltage Ubat directly on the network 9, and consequently to eliminate the voltage drop V introduced by the safety module 30.

(54) In this variant, the regulation module 39 additionally comprises first and second monitoring devices 41, 42, which make it possible to process respectively the case of breakage of a link between the measurement terminal 40 and the positive line 24, or the case of a failure of the second semiconductor switch 31.

(55) The first monitoring device 41 commands the opening of the first semiconductor switch 16 by inhibiting the pulse width modulated signal by means of a logic gate 43, when a first differential voltage V1 between the first supply terminal 25 and the measurement terminal 40 is greater than a first predetermined threshold.

(56) A first alarm A1 is sent to the dashboard by the first monitoring device 41, in order to indicate this disconnection of the measurement terminal 40 of the on-board network 9.

(57) The second monitoring device 42 commands the opening of the first semiconductor switch 16, by also inhibiting the pulse width modulated signal by means of the same logic gate 43, when a second differential voltage V2 between the measurement terminal 40 and the first supply terminal 25 is greater than a second predetermined threshold.

(58) A second alarm A2 is sent to the dashboard by the second monitoring device 42, in order to indicate this failure of the second semiconductor switch 31.

(59) The fact that the regulation module 1 and the safety module 30 are separate makes it possible to add a safety function easily to existing brush holders 18.

(60) In fact, in these brush holders 18, the regulation module 1 is connected electrically to a circuit of tracks (in thick lines) by interconnections of the bonding type, as described in association with FIG. 1.

(61) In the first and second embodiments of the invention, the safety module 30 can be added by bonding on the circuit of tracks whilst retaining the same regulation module 1, in order to obtain a regulator brush-holder 43 with a safety function which can be integrated in an improved alternator 44.

(62) It will be appreciated that the invention is not limited simply to the preferred embodiments described above. In particular, the type of semiconductor switch 16, 31 cited is non-limiting. Nor are the numerical values indicated limiting.

(63) Other embodiments would not depart from the context of the present invention, provided that they are derived from the following claims.