SAE J180-2002 Electrical Charging Systems for Off Highway Work Machines.pdf
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1、SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising therefr
2、om, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. TO PLACE A DOCUMENT ORDER: +1 (724) 776-4970 FAX: +1 (724) 776-0790 SAE WEB ADDRESS h
3、ttp:/www.sae.org Copyright 2002 Society of Automotive Engineers, Inc. All rights reserved.Printed in U.S.A. SURFACE VEHICLE 400 Commonwealth Drive, Warrendale, PA 15096-0001 STANDARD J180 REV. JAN2002 Issued1970-06 Revised2002-01 Superseding J180 MAY87 (R) Electrical Charging Systems for Off Highway
4、 Work Machines 1.ScopeThis SAE document describes alternator physical, performance and application requirements for heavy-duty electrical charging systems for on and off road applications including those defined in SAE J1116. 1.1PurposeThe purpose of this SAE document is to provide information on wh
5、ich to base machine and component design and to establish minimum requirements which will result in the most satisfactory operation of charging systems in construction, agricultural, and industrial machinery environments. 2.References 2.1Applicable PublicationsThe following publications form a part
6、of this specification to the extent specified herein. Unless otherwise indicated, the latest version of SAE publications shall apply. 2.1.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-001. SAE J56Electrical Generating System (Alternator Type) Performance Curve and
7、 Test Procedure SAE J551-4Test Limits and Methods of Measurement of Radio Disturbance Characterisitics of Vehicles and Devices, Broadband and Narrowband, 150 kHz to 1000 MHz SAE J1116Categories of Off-Road Self-Propelled Work Machines 2.1.2ASTM PUBLICATIONAvailable from ASTM, 100 Barr Harbor Drive,
8、West Conshohocken, PA 19428-2959. ASTM B 117Salt Spray (Fog) Testing NOV 85 2.2Related PublicationsThe following publications are provided for information purposes only and are not a required part of this specification. 2.2.1SAE PUBLICATIONSAvailable from SAE, 400 Commonwealth Drive, Warrendale, PA
9、15096-001. SAEJ551-1Performance Levels and Methods of Measurement of Electromagnetic Compatibility of Vehicles and Devices SAE J551-2Test Limits and Methods of Measurement of Radio Disturbance Characterisitics of Vehicles, Motorboats, and Spark-Ignited Engine-Driven Devices SAE J180 Revised JAN2002
10、-2- 3.Definitions 3.1Flat CompensationA regulator having flat compensation is one where the voltage setting remains near constant over the temperature range of operation. 3.2Temperature CompensationA regulator having temperature compensation is one where the voltage setting varies in relationship to
11、 temperature. 3.3Batteryless OperationOccurs in a machine application whenever the battery becomes disconnected from the alternator. The electrical load of the alternator is significantly different in this situation. The disconnection may be intentional or unintentional. In some applications, machin
12、es are shipped for export without batteries. In this situation, a slave battery may be used for jump starting the machine. After the machine is started, the battery is disconnected and the machine is moved. During movement the alternator is operating without the battery and expected to power such it
13、ems as the transmission and engine fuel solenoids. Batteryless operation can also occur during operational usage whenever there is: a. A battery open cell failure b.The battery becomes extremely sulfated c.The connections to the battery become loose d.The connections to the battery become corroded e
14、.A master disconnect switch becomes open or its connections become open. The effect of the alternator operating in a batteryless situation is typically a wider range of voltages in output than when loaded with a battery. Some alternators do not produce output without a battery. 3.4Reverse PolarityRe
15、verse polarity occurs when the battery positive and negative cables are hooked up in reverse. 3.5Load DumpA sudden interruption of most electrical loads from the alternator during alternator operation causing a self-induced voltage surge. Load dump could be caused by such items as connections to the
16、 alternator B+ terminal becoming loose, connections to the alternator B+ terminal being corroded, defective alternator output cables, etc. 4.Physical Requirements 4.1DimensionalFigure 1 portrays a spool-mount alternator. Figure 2 portrays a hinge mount alternator. Included in both are the proper pul
17、ley hub dimensions for the alternators in both envelopes. SAE J180 Revised JAN2002 -3- FIGURE 1ALTERNATOR DIMENSIONS FOR SPOOL MOUNTING SAE J180 Revised JAN2002 -4- FIGURE 2ALTERNATOR DIMENSIONS WITH HINGE MOUNTING 4.2Mounting Recommendations 4.2.1HINGE MOUNTINGFigure 3 shows a hardened split bushin
18、g in the alternator mounting lug opposite the drive end. The mounting bolt clamps the mounting bracket to this bushing. Tightening of the mounting bolts positions the bushing, easing strain on bracket and lugs. FIGURE 3TYPICAL INSTALLATION OF SPLIT BUSHING IN HINGE MOUNTING LUG SAE J180 Revised JAN2
19、002 -5- 4.2.2SPOOL MOUNTINGFigure 4 shows the hardware and brackets for spool mounting. A hardened, split bushing is located in the mounting bracket. FIGURE 4TYPICAL INSTALLATION OF SPLIT BUSHING IN BRACKET FOR SPOOL MOUNTING 4.3TerminalsOn all alternators, provisions shall be made for a negative gr
20、ound connection, either by a terminal post or a threaded hole, to insure a sound electrical ground path from the alternator to the machine system ground. To insure correct electrical connection between the alternator and the mating wiring harness, and to standardize on terminals between the various
21、alternator manufacturers, terminal sizes are recommended in Figures 1 and 2. Blade type external terminations are not recommended to be used on alternators that are covered by this SAE document. 4.4Shaft SizeSee Figures 1 and 2. 4.5Alternator IdentificationEach alternator shall be identified with th
22、e following characteristics: Manufacturers Identification, Part Number, Voltage Rating, Current Rating, Manufacturing Plant, and Manufacturing Date Code (and/or Serial Number). 5.Performance Requirements 5.1PerformanceRefer to SAE J56 for performance and test procedure. 5.2RegulationWhen engines run
23、 continuously for hours on end, battery charging systems require special voltage regulation considerations to maintain correct battery charging voltage. Possible regulation systems are: a.Flat compensated (see Figure 5): Nominal voltage ranges of 13.5 V to 14.5 V and 27.0 V to 29.0 V. If a direct re
24、lationship between battery temperature and regulator temperature is not known or applied, the regulator shall have flat compensation. Figure 5 depicts typical flat temperature compensation with respect to the regulated voltage. The curve shows a regulated voltage of 14.0 V is given for a specific op
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