INTRODUCTION

TO
THE
COMPANY
Company Profile

Name : DENSO India Pvt Ltd

(DNIN)
(Involved in the manufacturing of
automobile components and
spares for both four wheelers and
two wheelers.)

Year of : 1984
Establishment

Major : Alternator, Startor, Magneto,

Products CDI

Major Customers : Maruti Suzuki, Toyota, Honda, Hero Moto corp., Yamaha`

Certification : ISO/TS 16949, ISO 9002, OHSAS 18001, ISO 14001, QS 9000

Contact : Noida dadri Road, P.O. Tilpatta-203207,

Distt Gautam Budh nagar,(U.P.)
Tel +91-120-2-560140
Fax +91-120-2-560156
Denso History:-

Denso India was incorporated on November 22, 1984 and was

promoted by Shri Ram Fibres and Nippon denso Co. The
Company manufactures alternators/generators with or
without vacuum pump regulators. Effective October 19,
1994, the company's name was changed to Nippon denso
India Ltd. from SRF Nippon denso, Ltd. The Company
obtained the approval of the Government of India to the
change in Name in 1995.
The company is engaged in the manufacturing and supply of
electrical automotive components. The Company provides its
services to cater the needs of the Original Equipment
Manufacturers (OEMs). The Company's operations are located
in Haridwar, India. Its customers are Maruti Suzuki India
Limited (MSIL) and Hero Honda Motors Limited.
Denso India Ltd. has decided to establish new factory within
the existing premises of its Haridwar plant named as Unit III
of the company. No investment is envisaged in the initial
stage and only some of the existing lines at Greater Noida
Plant shall be shifted to new UnitIII at Haridwar Plant to
cater to the two wheelers segment of the auto industry.
After becoming independent from Toyota Motors, Nippon
Denso Co. Ltd. Nippon Dens Kabushiki-Gaisha) was founded
in 1949. About 25% of the company is owned by Toyota Motor.
Despite being a part of Toyota Group of companies, as of year
ended March 2016, sales to Toyota Group accounts for less
than 50% of the total revenue (44% of the revenue originate
from other car manufacturers in Japan, Germany, U.S. and
China).Currently, Denso ranks the fourth largest auto parts
supplier
Product knowledge :-

1 :- Alternator :
Alternator is a part of
charging system in
vehicle supplying d.c.
electricity to its
electrical components.
Three function of
alternator are:
Electricity generation
Rectification
Voltage regulation
ALTERNATOR BASICS :-

An alternator is an electrical generator that converts

mechanical energy to electrical energy in the form of
alternating current. In principle, any AC electrical generator
can be called an alternator, but usually the term refers to
small rotating machines driven by automotive and other
internal combustion engines. An alternator that uses a
permanent magnet for its magnetic field is called a
magneto. Alternators in power stations driven by steam
turbines are called turbo-alternators. Large 50 or 60Hz
three phase alternators in power plants generate most of
the world's electric power, which is distributed by electric
power grid.
 Principle of operation :-

Diagram of a simple alternator with a rotating magnetic core (rotor)

and stationary wire (stator) also showing the current induced in the
stator by the rotating magnetic field of the rotor.
A conductor moving relative to a magnetic field develops an
electromotive force (EMF) in it (Faraday's Law) This emf reverses
its polarity when it moves under magnetic poles of opposite
polarity. Typically, a rotating magnet, called the rotor turns within a
stationary set of conductors wound in coils on an iron core, called
the stator. The field cuts across the conductors, generating an
induced EMF (electromotive force), as the mechanical input causes
the rotor to turn.
Cut Section and Exploded view of Alternator :-

Cover

Frame
Rear
End

Frame
Drive End
Main Parts Alertnator :-

ROTOR STATOR RECTIFIER REGULATOR HOLDER

BRUSH
Rotor Function :-
Rotor: The Rotor function is to provide a magnetic
field and it rotate together with the shaft. This type
is called a rotary magnetic field alternator.
A rotor consist of a pole core (magnetic pole),
field coil, slip ring, shaft & other parts.
A pole core as shown in fig, is in a pawl shape and
contains a field coil. When current flows in the field
coil, one side of the core is completely all
magnetized to become N pole and another side
becomes S pole. With this form, called a pawl pole,
all poles are magnetized by one field coil.
As shown in fig magnetic flux in the inner part of
the pole runs in live with the shaft, then radically
on the pole core side to the pawl and enters the
stator.
As magnetic flux runs radically on the pole core
side, if ferrous material is used for front and rear
covers, they permit magnetic flux run-in them and
reduce the flux running pawls. This is the reason
why nonmagnetic material such as aluminum is used
for covers.
Two slip rings are provided at the one end of the
rotor to supply exciting current to the rotating
rotor. The ring is made of such material as copper,
bronze, stainless steel etc and S lines with the
insulating material. A brush is provided in contact
with the ring at its periphery to supply exciting
current.
Stator Function :-

STATOR
CONSTRUCTIO
N:
STATOR
CORE
STATOR COIL
TERMINAL
WEDGE

Features :-
1. Since the stator generates
the largest amount of
heat among other
components of the
alternator , a highly heat-
resistant coating is
applied to the coils.
2. The stator coils can be
connected in two ways :-
Y connection : Produces
high voltages . Most
popular at present.
Delta connection :
Produces high output
current
 Regulator Function Regulator
While engine speeds and
Role OF IC Regulator electrical loads change, the
alternators output must
1 Adjusts the field current (current remain even- not too much, nor
fed to the rotor coil) to control thetoo little.
generated voltage. The regulator controls
alternator output by increasing
2. Monitors the condition of the or decreasing the strength of
electricity generation and output the rotors magnetic field. It
warning when failure occur does so by controlling the
amount of current from the
battery to the rotors feild coil.
IG, L LIN Type
Type LI
N
I C
G
O
F
M
R

IG, L Type LIN Type

IG: Ignition Terminal LIN: Local Intranet Network Terminal

L: Lamp Terminal B: B+ Terminal
FR: Feedback terminal F: Field Terminal
COM: Communication Terminal P: Phase Terminal
B: B+ Terminal E: Earth Terminal
F: Field Terminal
P: Phase Terminal
E: Earth Terminal
Charging system :-
Charging system :-
 Introduction to Projects :-
1:- Modification in existing alternator design,
designing of name plate for it &testing its output.

2 :- Testing output of new alternator on alternator

test bench.
DENSO
PROJECT :- 1

Design Change Explanation

Maruti Suzuki India
Ltd.
DENS Engineering, R & D
O

Design
Change
Points
Name: Alternator Assy.
W/Regulator
Model: SE08B - 80A (YJC Diesel)

Denso India Ltd.

Product
Engineering
 3/
2. Change Point Details 12
YJC-D Alternator S.
Items YP8MC-D YJC-D
Base Model: YP8MC-D N
(SR104211-2160)
Alternator Pulley
Assy. (Clutc
h

type)

Fram
e DR 3 4 Rotate
anticlo
8 7 ckwise

Fram
e RR Rotat
e
antic
4 lock
7 wise

3
8

Stator
Assy.
S.
Items YP8MC-D YJC-D
N

Beari
Regul ng DR
ator & RR
Assy.
DR
RR

Rotor
Assy.

Name
Plate
ID Code & Color
different
Rectif New due to
ier Frame RR Mtg
angle change
assy.
 Base Model:
Change Point Description YP8MC-Diesel
YJC-Diesel
YP8MC-
Diesel
SE08B
(80A)

YJC- Mountin
Diesel g Rotate
SE08B
(80A)

Mounting
Rotate 9
Performance Graph

5000 rpm is the standard criteria

for performance measurement in
Hot Condition
Hot Condition
means
Alternator should
run on 5000 rpm
@25C for 30
minutes
continuously
PROJECT 2:-
2:- Testing of new alternator :
Alternator Test Bench - ALT 72B

Alternator Test Bench - Outside structure

Alternator Test Bench - Hot & cold

Std. Parameter
Alternator output performance at25C Cold

Alternator output performance at 25C Hot

(Running 5000 rpm for 30 min)

Alternator output performance at 90C Hot

(Running 5000 rpm for 30 min)
Alternator mount on fixtures with proper
fastening.

Connect properly B+ Terminal for output.

Machine belt alignment should be properly

with alternator pulley. .

Performance check trough

automatic program.

Output performance
Alternator voltage
Environment temp. Environment temp
Alt. rpm
TESTING PROCEDURE :-
Step & key point Reason

Test bench preparation before testing:-

-check main switch on
-check master is on Machine will not run
-check air pressure valve should be 4 bar
-check door is lock

Select the proper fixture according to Alternator will not mount
alternator mounting & fix it on machine
base plate

Select the belt according to the pulley Belt wear will occur
grooves

Put alternator on fixture and apply belt on Belt wear will occur
pulley and check belt alignment

Adjust mounting fixture of alternator in >Belt wear will occur
such a way that belt attains appropriate >output performance will hamper
tension

Alternator should properly tight on fixture Accident may happen

Place reflecting tape on surface of pulley for Calculation of RPM can be wrong
proper RPM measurement

Place tachometer in front of pulley and Calculation of RPM can be wrong
keep distance of 3-8 mm

Fastening earth wire on alternator & Voltage drop will occur
mounting fixture ( thick wire in fixture and
thin wire on alternator)

Wire B+ (red colour) should be attached >sparking will occur
with alternator B terminal >output will be less

Select coupler according to regulator Fitment will be NG
shape and spec.

Environment temp sensing wire to be Performance will be effected

placed near rear side of alternator & keep
it as 50-70 mm dist.

Go to A-100 measuring system, the icon
available on Pc desktop

Select the part number for testing the Miss judgement and wrong
alternator from drop down items performance

Select the version of the test like sweep M/C cannot run & wrong
end , torque judgement

Check door lock or not M/C will not run

In case of 25 degree c cold test only put Wrong performance
temp 25 degree c and other parameter
zero

In case of 25 degree c hot test put temp Wrong performance
25 degree c duration time 30 min.& Rpm
5000

In case of 90 degree c hot test put temp Wrong performance
25 degree c duration time 30 min.& Rpm
5000

Note. After that m/c will run automatically
& generate data
File location : c\program files\D&V
Electronics LTD\A-100 measuring tool
Thanks