Troubleshooting Alternator Wiring

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wcorey
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Re: Troubleshooting Alternator Wiring

Postby wcorey » Thu Sep 19, 2013 4:34 am

____ As you load-tested with resistance-values that continually moved further away from .2-ohms, the resulted wattage should've likewise continually diminished.


No, as I went down in resistance values the output decreased steadily, regardless of which coil configuration. I just tried a .5ohm resistor (with the large coil in parallel config) and got 12w. It goes up gradually to almost 14w all the way into double digit ohms. Slightly improved with the addition of the caps and a bit more with the mosfet r/r.
I have a large resistor with an open side that a contact can be moved along to get various values. My meter gets somewhat flaky readings down under a half ohm so not entirely sure what the actual values were but as I moved the contact down the outputs got lower. At the end, what I think was aprox .2ohm or a bit less, output went down to .6vdc, 4.3a.
Put both coils (individually having both windings wired in parallel) in series and just as before only got a few more watts.


____ Well yeah but, not so considerate for all the OTHER readers.


What other readers? Show of hands please...


But didn't we discover that Ducati had actually bothered to wind the small power-coils oppositely from the direction chosen for the large ones ?


Maybe, I never got that straight, or figured out a way to test for it short of physically unwinding a coil (which I never did). Bruce?
Even if they did, It may have been simply for the more convenient placement of the connections.


____ Even-so however, there should still be some 'leftover' power to be measured, (as the large-coil should overpower the smaller one).


Why I said "CLOSE to no output". It also applies to the pair of windings on the an individual coil (stock as well as rewound) when wired in series, backwards = low or no output, respectively.



__ I assume that you always tested the pair of coils with them loaded onto stator-core fingers that were next-door neighbors ? ...


Yes


I think it would be a worthy test to try the two power-coils loaded onto the core-fingers located at the 9 & 3 o'clock positions, with a series-connection made between those two power-coils.


Likely not going to happen, it's simply inconvenient to remove another never-been-removed stock coil on the stator and then have to re-setup the test rig, unless of course there is further evidence that this would change things in some significant way.


What further requests (before I reduce the windings as per Bruce's request)?

I've tried most every combination of things (within reason) I can think of to try and have seen no change in the trends.
I know this whole thing seems to be an inexplicable conundrum that we'd love to have an answer to but IMHO it's time to just let it go, feels like I'm chasing my tail at this point. Wouldn't be the first time in the history of this project that something didn't work out as planned/theorized.

machten
Posts: 507
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Re: Troubleshooting Alternator Wiring

Postby machten » Thu Sep 19, 2013 5:13 am

What other readers? Show of hands please...


I'm reading with interest Bill! I read all of the previous post last time too.

I confess that it's a bit like French for me - I can read it and have some grasp of what is being said, but for me to write anything would just result in embaressment for me and delay for you guys explaining stuff. ;)

Carry on, chaps! I think you'll find a lot more people than you might think are reading this and at least one of those would look forward to an "Alternator Wiring for Dummies" summary after you fellas are done.

regards,

Kev
Last edited by machten on Thu Sep 19, 2013 1:05 pm, edited 1 time in total.

graeme
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Re: Troubleshooting Alternator Wiring

Postby graeme » Thu Sep 19, 2013 6:19 am

"What other readers? Show of hands please..."

I'm still sitting quietly in the corner watching the smart people play with electricery,,,,,,,,, :oops:

Most of what I have read is way over my head. :oops: :oops:

Plus One Kev.

Graeme

Harvey
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Re: Troubleshooting Alternator Wiring

Postby Harvey » Thu Sep 19, 2013 9:41 am

Yes I'm here, can't wait for the end result. :)
Harvey.

ecurbruce
Posts: 313
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Location: Hurricane mills TN

Re: Troubleshooting Alternator Wiring

Postby ecurbruce » Thu Sep 19, 2013 11:48 am

First, thanks, guys for following, I'm anxious to see where all of this goes as well, hopefully something benefitial...

Bill says;"Ok, I tried connecting the two windings (on one coil) in series, picked up 2-3 more watts across the board than the previous figures.
Both coils in series/series (with each other), most I got was 26w.

On that line of thought, connecting an entire spool as if it was one winding gives a specific output reading.
How does that spec. compare to... An origional "Ducati" spool of the same size with it's windings connected as if they were one continuous wind? Would this not tell us if we were getting any gain from the extra length of wire?
If we are getting a gain, is it enough difference to make it worth continuing?

Bob says;"But didn't we discover that Ducati had actually bothered to wind the small power-coils oppositely from the direction chosen for the large ones ? "

It seems that we did discover windings in different directions, I should go dig that out (again), but it's not as important as the relationship of the winding and the magnetic field, and whether the winding starts clockwise or counter-clockwise is only relative to beginning at the inside of coil or outside of coil. For instance if you have a core that is standing straight up and down, wound clockwise- north would be "up", wound counter-clockwise, north would be "down". It doesn't matter how that wire got on that core, as long as its hooked up for the flow to go clockwise for north up, or counter-clockwise for north down.

Bruce

wcorey
Posts: 323
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Location: MA USA

Re: Troubleshooting Alternator Wiring

Postby wcorey » Thu Sep 19, 2013 1:48 pm

Ok, I stand corrected on the show of hands, good on you guys for hanging in.
Sorry for being a little ambiguous with the details but learned from past experience here to prioritize these things in triage mode. Unless test results quickly show something promising, I can't help but look at it as yet another interesting dead end and hesitate to waste more valuable time on it.

Don't hold you're breath for 'end results', lol, this whole alternator thing has so far proved to be truly endless.
Or maybe the snake eating it's own tail sort of thing...


On that line of thought, connecting an entire spool as if it was one winding gives a specific output reading.
How does that spec. compare to... An origional "Ducati" spool of the same size with it's windings connected as if they were one continuous wind?


We went through that already with the 'Grand series' testing, can't recall if there were figures for a single coil but there certainly were for dual coils.
It's all back there somewhere...
That said, if/when I go back into the stator for a reconfig, I'll hook up a couple stock coils for comparison.

Here you go, just went and dug up some old notes on two coil tests. Roughly the same result, oddly enough...
I'll dig up my 'index and synopsis of test results' to the old thread and put it up here at some point, has been a big time saver for me.

Grand series
3450rpm, one set, A/B

1ohm----4.3a----4.5vdc----19.4w
2ohm----3.6a----7.3vdc----25.8w
3ohm----2.9a----8.7vdc----26.1w
4ohm----2.4a---10.0vdc----24.4w
5ohm----2.2a---10.6vdc----22.5w



If we are getting a gain, is it enough difference to make it worth continuing?


In the name of science and curiosity, yes.
For expecting practical gains that would be worth the effort of an entire rewind... To be determined, hopefully, though at this point my confidence is low.

In practical terms (for the good of 'the community') it would be much more productive to pick up where we left off in the old thread.
Bob isn't having any of that though...

machten
Posts: 507
Joined: Sat Jan 01, 2011 12:57 pm

Re: Troubleshooting Alternator Wiring

Postby machten » Thu Sep 19, 2013 3:49 pm

Ok, I stand corrected on the show of hands, good on you guys for hanging in....

Don't hold you're breath for 'end results', lol, this whole alternator thing has so far proved to be truly endless.
Or maybe the snake eating it's own tail sort of thing...


And..

First, thanks, guys for following, I'm anxious to see where all of this goes as well, hopefully something benefitial...


I'd ask you fellas to seperate the lack of contributions from other people to this thread from its interest and value to people. You guys are operating on a different plane in this field to most of us mere mortals, I suspect.

Personally, one of the things I'm really looking forward to, is after you guys arriving at your conclusions, trolling back though this whole thread and looking for some "light bulb" moments for my own education.

Avanti!!!

Kev

ecurbruce
Posts: 313
Joined: Fri Apr 01, 2011 12:43 am
Location: Hurricane mills TN

Re: Troubleshooting Alternator Wiring

Postby ecurbruce » Thu Sep 19, 2013 4:40 pm

Kev,
Thanks...but I'd have to group myself in with the mortals :)
Listen, I just have to be comfortable with embarrassing myself, as it's a common occurance on my part!
It's amazing what you can learn from all the stupid questions and opinions.
I didn't know ANY of this when I started.
This is all just for fun, for me, and as long as it stays that way, I'm in!

Don't discount your experience and contribution with these little machines, it's something the younguns can never catch up to.

Bruce

DewCatTea-Bob
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Location: Near SE side of Lake Michigan

Testing-outcome Conundrum

Postby DewCatTea-Bob » Sat Sep 21, 2013 12:00 am

____ EMBARRASSING ! - Stupid-me ! ... Here I've been left on page-13 since the 18th, patiently waiting for a new post from Bill,, and not-realizing that page-13 was already filled-up with it's 10-post limit !
Luckily, my Firefox-browser chose to crash (for some unknown reason when I wasn't using it),, and then just recently reopening it, has now allowed me to discover that page-14 had long-before come-into existence !
__ Instead of posting on THIS-page (as I should've been doing), I've been adding to my last-post on the previous-page, (as can be seen done in blue-wording),, and-so likely no-one has noticed what I've added to that post (since the 18th).
__ NOW, it's going to take me too-long to respond to everything that's been transpiring on THIS-page.
But I'll try to get caught-up with most of the rather important stuff by the next few hours.



wcorey wrote:
____ As you load-tested with resistance-values that continually moved further away from .2-ohms, the resulted wattage should've likewise continually diminished.


No, as I went down in resistance values the output decreased steadily, regardless of which coil configuration.
____ I'm left to gather that what it seems that you're saying, is that as you lowered the resistance-level of the test-load (from 11-ohms ?), the resulted consumed-wattage also accordingly decreased along-with as well ?
__ Anyhow, that actually makes fair sense,, cuz my quoted-statement stupidly neglected to also take into account the 'impedance' factor which will ADD-to the .2-ohms of mere resistance, (although I had indeed previously remembered to include that additional factor as a relevant factor to be kept under consideration).
STILL however, (as you must already realize),, once the upwardly-increased (from .2-ohms) resistance-level of the test-load has been set to exceed the resistance/impedance-level of the power-winding under testing, then the power being consumed (by the test-load) will also begin to fall-downward, in that direction as well.



" I just tried a .5ohm resistor (with the large coil in parallel config) and got 12w. It goes up gradually to almost 14w all the way into double digit ohms. "

____ I assume this to mean that with the large-coil left arranged with it's double-winding connected in parallel, that a 1/2-ohm load-resistance resulted with 12-watts consumed,, but yet a number of higher values of trialed test-loads (possibly exceeding 11-ohms) only found just 2-watts more (over a very-WIDE range).
Which leaves the question as to just how high the load-resistance can get before the consumed-wattage falls-off back-down to under 12-watts !?
It seems that the impedance-factor is so very spread-out, that something-else must be involved to prevent it from more normal/peakyer peaking. _ I had of-course expected some impedance* to be added to the resistance of the power-winding, but not so much over such a WIDE-range !
(* 'Impedance' is a form of resistance that affects the flow of AC [or even pulsating-DC] type of current, and it's resistive-effect is intensified as frequency is increased, [due-to fighting the flywheel-effect of flowing-current]!)
__ It would be quite interesting to know-of the results of the same-testing but with the double-windings rather connected in SERIES (instead of parallel) !



" Slightly improved with the addition of the caps and a bit more with the mosfet r/r. "

____ To help narrow-down the test-circuitry so that there's less chance for unexpected factors, (not to mention somewhat easier to set up),, we probably ought-to consider connecting the test-load DIRECTLY-to merely-just the raw power-output of the tested power-winding itself, alone. _ That way, we could then possibly see what's happening exactly where.



" what I think was aprox .2ohm or a bit less, output went down to .6vdc, 4.3a. "

____ Probably pretty-close to a short-circuit at that point.
__ The test-load should never be allowed to become less than the power-winding's 'resistance'.



" Put both coils (individually having both windings wired in parallel) in series and just as before only got a few more watts. "

____ I gather that you mean to indicate that you connected both the small & large power-coils together in series (whilst keeping both their double-windings left in parallel), which thus should've been the "main/intended-test" (that was most expected to be conducted).
But your included wording: "and just as before only got a few more watts.", leaves me wondering 'a few more watts than what?'.



" What other readers? "

____ Have you not noticed the well-over1000 hits that this thread has accumulated ?
__ I'm sure there's likely some unregistered followers in addition to those who've let you know.



" Maybe, I never got that straight, or figured out a way to test for it short of physically unwinding a coil (which I never did).
Even if they did, It may have been simply for the more convenient placement of the connections. "

____ I would tend to agree that the reasoning for alternated winding-directions would only be due-to more convenient/shorter wire-connections between the neighboring power-coils, but then that good-reasoning gets fairly shadowed since the outlet-locations of the interconnecting lead-ends don't exactly follow-suit very-closely in that sensible regards.
__ I'm thinking that since the magnetic-poles (of the mag.rotor) alternate N/S/N/S/N/S,, that then logically, the coil-windings thusly need to ALSO alternate in direction correspondingly, so that THEIR very-OWN produced magnetic-fields are kept in coherent-harmony with the fields of the rotor-magnets (so that no magnetic-field cancellation [between the two field-sources] could possibly occur).
So just as electrical-polarity is-not something that can be ignored,
MAGNETIC-polarity should-not be overlooked either ! _ As both polarity-types ought-to be considered as equally important !
__ So it seems fairly important (to ME) to find-out if Bruce had wound his pair of power-coils OPPOSITELY, or not !?
If it's not obvious as to whether both coils are wound oppositely from one-another, or not,, then a small DC.source could be (identically) fed into both power-coils, and if wound oppositely, then one coil should attract the N.pointer of a compass while the other-coil repels it (and instead attracts the S.end).


Bill wrote:
____ Even-so however, there should still be some 'leftover' power to be measured, (as the large-coil should overpower the smaller one).

Why I said "CLOSE to no output". It also applies to the pair of windings on the an individual coil (stock as well as rewound) when wired in series, backwards = low or no output, respectively.
____ RIGHT, all quite-sensible ! _ Just checking to make-SURE (that all adds-up as it ought-to).


Bill wrote:
__ I assume that you always tested the pair of coils with them loaded onto stator-core fingers that were next-door neighbors ? ...

Yes
____ Your disappointing test-results had led me to hope that you had-not done-so, and perhaps had-not bothered to make-sure that the pair of power-coils were located under oppositely polarized mag.fields.
__ Now my (similar) hopes lay with the possibility that Bruce's two separate winding-jobs were-not done oppositely.


Bill wrote:
I think it would be a worthy test to try the two power-coils loaded onto the core-fingers located at the 9 & 3 o'clock positions, with a series-connection made between those two power-coils.

Likely not going to happen, it's simply inconvenient to remove another never-been-removed stock coil on the stator and then have to re-setup the test rig, unless of course there is further evidence that this would change things in some significant way.
____ I really don't think that it would change anything in any significant way, (but still might learn something however).
When I stated "the two power-coils", I had specifically meant BRUCE's coils,, so now assuming that you had correctly realized that, I thusly gather that he hadn't also sent you a bare stator-core to go-with.
So in that case, never-mind.



" What further requests (before I reduce the windings as per Bruce's request)? "

____ Please hold-off on that until I'm sure we haven't got anywhere-else to proceed onward to.



" I've tried most every combination of things (within reason) I can think of to try and have seen no change in the trends. "

____ Wish I could've watched-over while you did-so, so I'd then know whether you possibly overlooked anything.



" I know this whole thing seems to be an inexplicable conundrum that we'd love to have an answer to but IMHO it's time to just let it go, "

____ I-myself just can't feel that way, and never would unless another independent tester also came-up with the EXACT-SAME results which you have.



" Wouldn't be the first time in the history of this project that something didn't work out as planned/theorized. "

____ I well recall (most of) my past training in this technical-field (of power-generation & electrical-motors, etc.), and I was taught all the various factors that yield the strength of power-output,, and wire-LENGTH was one of the main-factors !
Now I thought that the positive effect of extended length was a straight-forward/linear type of outcome, (meaning that doubling the length would equally double the tension),, but perhaps the relationship is actually rather a diminishing-returns type of outcome, (but that doesn't make good/logical-sense to me).


Hopeful-Cheers,
-Bob
PLEASE NOTE... If this-post is not-yet signed-off with '-Bob', then I'm still in the process of completing it,, and if not also included with 'DCT' near bottom as well, then I may edit this post's wording at a later time. - Dct.Bob

DewCatTea-Bob
Posts: 2897
Joined: Sun Nov 01, 2009 10:53 am
Location: Near SE side of Lake Michigan

More-detailed / Elaborated-explanationing

Postby DewCatTea-Bob » Sat Sep 21, 2013 9:36 am

[quote= graeme ...
" Most of what I have read is way over my head. "

____ If you would ever like some related detail more simply explained, I'd be willing to tackle such task for you (or anyone-else) !


Hopeful-Cheers,
-Bob
PLEASE NOTE... If this-post is not-yet signed-off with '-Bob', then I'm still in the process of completing it,, and if not also included with 'DCT' near bottom as well, then I may edit this post's wording at a later time. - Dct.Bob


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