48V Hybrid Synchronous Alternator for Sprinter with 12V 3000W Auxilliary Power

Scotty AI V3 and Permanent Magnet Hybrid Alternator Control are perfect partners

1. CAN Communication Protocols:
   • The HES Alternator supports standard CAN commands from a supervisory controller.
2. Supervisory Control:
   • Through CAN commands from SCOTTY AI V3, the voltage and current limits for the alternator can be set based on the charging requirements of the high side 48V lithium battery. This feature is crucial for optimizing the alternator’s performance based on battery type and system requirements.
   • The alternator uses closed-loop control algorithms to maintain precise output voltage and current levels set by Scotty AI. Feedback from the system is monitored and processed to adjust the output dynamically, ensuring safe and efficient charging.
3. Modes of Operation:
   • The alternator can operate in several modes configured by Scotty AI:
     • Torque Mode: Limits output based on torque constraints.
     • Generator Mode: Produces power based on predefined voltage/current settings.
     • Autonomous Mode: Allows operation without external control, using pre-configured default settings.
     • Idle Mode: Zero output when not required, reducing engine load.
4. Integrated Inverter with Load-Dump Protection:

1. • The alternator features an integrated inverter that includes load-dump protection circuits. These circuits detect sudden increases in voltage and respond by clamping the voltage to safe levels, preventing damage to the alternator and downstream electronics. I
   • In the event of a load dump, the software can adjust the alternator’s output to mitigate the effects of the voltage spike, ensuring stable operation.

1. Benefits of CAN-Based Control

• Precise and flexible adjustments.
• Compatibility with modern Vehicle Engine Controls.
• Enhanced safety through built-in diagnostics and monitoring.
• Efficient integration into multi-device systems (e.g., combining alternators, batteries, and DC DC Controllers).

1960’s

5.5kW output at 60-70% Efficiency

2024’s

8.6kW output at 84% Efficiency

1. Traditional Alternator with Diode Rectifier:

• Working Principle:
  • Converts mechanical energy to electrical energy using a rotating electromagnetic field.
  • Uses a diode rectifier to convert the AC output into DC.
  • Excitation is provided by a DC supply to generate the rotor’s magnetic field.
  • Remote regulators that control this field current are brands like Wakespeed, Balmar and Zeus.
• Features:
  • Relies on mechanical excitation (often through brushes and slip rings).
  • Inefficient at partial loads due to fixed excitation.
  • Cannot dynamically adjust magnetic flux.
  • More wear and tear due to mechanical components like brushes.
  • Vulnerable to a load dump if the power circuit is opened before the field control circuit can collapse.
• Applications:
  • Simple, cost-effective systems since the 1960’s with low efficiency requirements.

2. HESA (Hybrid Excitation Synchronous Alternator):

• Working Principle:
  • Uses hybrid excitation: permanent magnets (for baseline excitation) and field current (for flux adjustment).
  • Does not rely on diode rectification since the AC output is converted to DC by an integrated DC inverter.
  • Variable frequency control, in consideration to efficiency and noise, vibration, and harshness (NVH)
  • FOC (Field-Oriented Control) algorithm combined with MTPA (Maximum Torque Per Ampere) technologies
• Features:
  • Combines high efficiency of permanent magnets with the controllability of electromagnetic excitation.
  • Magnetic flux is dynamically adjustable, improving performance across varying speeds and loads.
  • No brushes or slip rings as it is a brushless design, leading to lower maintenance.
  • When controlled by advanced CAN controller, load dumps are completely avoided.
• Applications:
  • Electric vehicles (EVs).
  • Renewable energy packages.
  • High-efficiency industrial drives.

Diode Rectifier
AC Alternator output conversion to DC Power

Inverter Technology
AC Synchronous Motor to DC output Power