Quality improvement from year to year

 

   We have been producing regulators since 2009 and are constantly improving quality by eliminating the causes of failure. It has been shown that the filling mass is a key factor in the durability of the regulator. The quality of the grout is ensured by special preservation of the components to prevent undesirable and invisible degradation. By implementing these special measures, there have been virtually no failures since 2018 (about 870 regulators have been produced since then). In the last 4 years, there were no cancellations of 620 regulators.   

 

Serial principle of operation as a major contribution to the quality and reliability of battery charging

 

   Compared to the vast majority of factory regulators, our regulators work in serial mode . Of course, we also offer other types of regulators, but we primarily produce serial types of regulators. Serial types of regulators have a number of advantages that additionally affect quality. Parallel regulators short-circuit the generator and even slightly increase the current when the set battery voltage is reached. Mosfet parallel regulators heat up even less because they have a smaller voltage drop when the generator is short-circuited than thyristor regulators, but the current from the generator with them is even higher by some percentage. Series regulators correct only the consumption current and only the consumption current passes through the stator windings. This is one of the frequent reasons for using our series regulators.

 

• The heating of the stator is reduced, which contributes to the reliability of the motorcycle, because the probability of burning out the stator and failure to charge the battery is reduced.

 

• Only consumption current flows through the regulator and the heating of the regulator is reduced. A less heated regulator will have a longer life.

 

• Lower current from the generator reduces the heating of the connector and wires from the generator to the regulator, and extends the life of the connector and reduces the probability of failure in the battery charging circuit.

 

• The serial principle of operation is the one that enables the temperature protection of the regulator from overheating (this is not possible with regulators with parallel mode of operation).

 

   You can read more about the comparison of series and parallel regulators in the article "Advantages of a series regulator". Here is also "Animated diagram of AC generator currents with series and parallel regulator at Ip=50% Imax".

 

Temperature protection

 

   Series regulators are equipped with a temperature sensor and are automatically switched off when the temperature of the refrigerator exceeds 70°C. The temperature sensor is located near the thyristor and prevents unnecessary overheating of the regulator in time, which could result in permanent failure of the regulator. It is better to turn off the regulator when it overheats and turn it on again when it cools down, than to overheat and destroy it. Along with moisture, high operating temperature is the second biggest factor in regulator failure. With the help of temperature protection, the electronics are protected from unforeseen overheating that leads to complete failure of operation.

   

Overvoltage protection

 

   Serial regulators are equipped with protection against excessive voltage from the generator, which instantly activates the rectification of the current to the battery and thus breaks the voltage. Without this protection, there could be a voltage breakdown of the power semiconductors and failure of the regulator. Series-parallel regulators have triple overvoltage protection. If too high a voltage appears from the generator, the series rectification is activated first, and if it fails, the parallel regulator is activated at a slightly higher voltage. The parallel regulator is quickly activated even if the output voltage exceeds 35Vp and thus protects the control electronics in case the battery does not take over the charging current (loss of connection with the battery). Ordinary series regulators will most likely fail, if the connection with the battery is broken. Even poorly designed parallel regulators can be destroyed when the connection between the regulator and the battery is broken. We know from experience that a voltage over 50Vp may momentarily appear on the output terminals of the regulator due to the operation of the electromechanical devices on the motorcycle. Our serial regulators are capable of withstanding over 100V instantaneous voltage jump without any consequence on further operation.

 

Semiconductors

 

   During operation, there is a very small number of failure cases related to power semiconductors. Before the assembly itself, the semiconductor housings are ground and polished in order to make them adhere to the cooler as well as possible. Yes, it is unbelievable, but even semiconductors from well-known manufacturers are not what they used to be. The unevenness is up to 0.1 mm, and the quality of the regulator without grinding and polishing would be significantly worse. Diodes and thyristors were selected according to the criterion of the smallest voltage drop, the best heat dissipation in the operating mode up to 50% of the rated current.

 

Control electronics

 

   The control electronics are designed to easily withstand overvoltages on the +12V power supply according to auto-moto standards up to 100Vp. Only voltages over 160V can permanently damage the regulator. Because of this, there was almost no failure of the control electronics due to excessive voltage. The control electronics itself does not contain electrolytic capacitors, which age and change their characteristics significantly faster than other elements.

 

   The control electronics also feature a micro ampere consumption. The standard regulator needs only 68uA for the operation of the control electronics. HVSP regulators consume up to 136uA. Because of this low consumption, the only drawback of control electronics is sensitivity to moisture penetration. The new elastic filling compound (from the middle of 2018.) and the special preservation of the polyurethane components guarantee good polymerization and protection against moisture penetration. Adhering to these principles in production, there are no more rare failures of control electronics.

 

Battery life on a motorcycle

 

   In contact with customers, we found out that as a side effect of using our serial regulators, the battery life has been extended. We have unusual cases of battery life of 8 and 6 years for regulator models prior to 2014. At that time the serial regulator was set to a minimum voltage of 14V. According to the manufacturer's recommendations, this is the optimal battery voltage for maximum battery life.

 

Adjustment of the regulator for maximum durability

 

   It is best to place the regulator in a place with good ventilation, where it is not exposed to heat from the engine or radiator, and where it is not splashed by water, mud and stones from the wheels. Also, the regulator must not be washed with a high-pressure cleaner because it may become contaminated with water and it will stop working.