Rectifier-stabilizer for motorcycle YAMAHA XV 400. Encyclopedia of radio electronics and electrical engineering

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In the YAMAHA XV 400 motorcycle, the rectifier-stabilizer of the on-board voltage failed. Since the block with the rectifier and control device, installed on the heat sink, is filled with compound, its repair turned out to be impossible. It was not possible to purchase a new block or similar. The car's on-board voltage regulator is not suitable.

Therefore, it was decided to develop and manufacture a home-made rectifier-stabilizer. It must ensure the conversion (rectification) of the three-phase alternating voltage of the generator into the direct voltage of the on-board network and maintaining it within 13,8 ... 14,2 V at a current consumption of up to 15 A. It was supposed to use the parts available or available for purchase in the unit .

Fig. 1

The result of the work was a simple and successful, in our opinion, design. The schematic diagram of the block is shown in fig. 1. Rectification of the three-phase alternating voltage generated by the generator is performed by diodes VD1-VD6. Maintaining the voltage of the on-board network within 13,8 ... 14,2 V occurs by closing each phase of the generator with its excess voltage to a common wire with trinistors VS1-VS3.

To control the trinistors, the control device A1 is used. The voltage level is monitored by the overvoltage detector DA1. The motorcycle's on-board voltage is applied to the detector input through a voltage divider R12-R14, which steps down the 14,2V voltage to about 4,7V (detector switching voltage). Trimmer resistor R13 is designed to accurately set the stabilization voltage. Capacitor C1 smooths out voltage ripples at the input of the detector.

Transistors VT1, VT2 provide amplification of the output signal of the detector to a level that ensures stable control of trinistors. LED HL1 is used for visual control of the block. Power is supplied to the stabilizer when the motorcycle ignition is turned on. While the voltage of the on-board network does not exceed 14,2 V, the voltage at the detector input (at pin 1) is less than its switching threshold, and at the detector output the voltage is in the range of 0,4 ... 0,6 B. In this case, the transistors VT1, VT2 remain closed, the voltage is not supplied to the control terminals of the trinistors VS1-VS3, they are also closed.

As soon as the on-board voltage exceeds 14,2 V, the voltage at the detector output will increase abruptly to 4,5 ... 5,2 V. This will lead to the opening of transistors VT2, VT1. An opening voltage will be applied to the control terminals of the trinistors. Through the opened SCRs, the windings of the alternator will be closed to a common wire. As a result, the voltage generated by the generator will decrease, which means that the voltage of the on-board network will also decrease. The presence of an opening voltage on the control outputs of the trinistors will be indicated by the HL1 LED.

When the onboard voltage is reduced to 13,8 V, the voltage at the input of the DA1 detector will become less than its switching threshold, and at the detector output it will abruptly decrease to its original level. Transistors VT1, VT2 will close, and after them the trinistors VS1 - VS3 will close. The voltage generated by the generator will again begin to increase until a new switch of the DA1 detector. The process of opening and closing the trinistors is continuously repeated, as a result of which the voltage of the on-board network is in the range of 13,8 ... 14,2 V.

Rectifier diodes VD1-VD6 can be used any, designed for forward current of at least 25 A and reverse voltage of at least 100 V. Trinistors VS1-VS3 must have a permissible forward current of at least 10 A and a direct non-opening voltage of at least 100 V. Instead of KT814B, you can use transistor KT816B, and instead of KT3102BM - KT3117A.

The overvoltage detector KR1171SP47 can be replaced by another from the same series with an operating threshold of no more than 13 V, but in this case it will be necessary to recalculate the resistance of resistors R12, R14 so that at a controlled voltage of 14,2 V and the position of the resistor R13 slider close to the average , the detector was switched. Trimmer resistor R13 - SP4-1.

The elements of the A1 control unit are placed on a printed circuit board made of fiberglass laminated on one side with a thickness of 1 mm. The board drawing is shown in fig. 2. To protect the assembled device from atmospheric influences, after adjustment, it is coated on both sides with two or three layers of varnish UR-231 or FL-582. In this case, it is necessary to protect the head of the screw that moves the engine of the resistor R13 from getting protective varnish on it.

Fig. 2

Diodes VD1-VD6 and trinistors VS1 - VS3 should be installed on a heat sink with a usable area of ​​at least 500 cm2, insulating them with mica spacers. Resistors R1-R6 are soldered directly to the terminals of the trinistors. Wiring circuits of rectifier diodes and trinistors (except for control circuits of trinistors) must be performed with a wire with a cross section of at least 2,5 cm2.

The unit is installed on the motorcycle in a place where its heat sink is blown with an oncoming air flow.

When adjusting, you must first set the trimmer resistor R13 to the top position according to the diagram. Pins 2 and 3 of node A1 are connected to a DC source, which allows you to smoothly adjust the output voltage from 12 to 15 V. Turn on the source and set its output voltage to 14,2 V. Smoothly move the slider of the resistor R13 until the HL1 LED turns on.

If we now reduce the output voltage of the power supply to 12 V, the HL1 LED will turn off. By smoothly increasing the output voltage of the power supply, make sure that when the level of 14,2 V is reached, the LED turns on and shines with a further increase in voltage. With a smooth decrease in the output voltage of the power supply, the HL1 LED should turn off at a voltage of 13,8 V and remain off with a further decrease in voltage.

After installing the unit on the motorcycle, make the final adjustment. They start the engine and, by the glow of the LED on the control board, make sure that the unit is in good condition and that it is connected correctly. Use a combined instrument or digital multimeter to check the voltage at the motorcycle battery. If necessary, resistor R13 sets the voltage on the battery to 14,1 ... 14,2 V. After that, it is necessary to cover the screw of the resistor R13 with auto-sealant.

Manufactured according to the proposed scheme and installed on a motorcycle YAMAHA XV 400, the rectifier-stabilizer worked flawlessly for a run time of more than 4000 km. At the same time, no undercharging of the battery or boiling of the electrolyte was noted.

Author: V. Perolainen, Yu. Prusakov, Balashov, Saratov region; Publication: radioradar.net

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