36/42 Volt Systems Are Coming ! By: A.S.T. Training Copyright 2001

Why is it called a 42 volt system ? The multiple factor: 1. 6 volt battery/7 volt charging….x volt battery/14 volt charging…x volt battery/42 volt charging…

Why do we need this ? Too many electrical loads present. Avoid today’s brownout conditions. Preparation for future advancements.

When can we expect this ? Conflicting reports as to who will have it first. Generally speaking the first vehicles should be released in BMW, Corvette, Nissan, Renault. Main stream by 2005.

What is in store for technology ? Disappearing drive belts. Electric water pumps. Electric A/C compressors Electric power steering racks. Electric brakes and suspension. Electric valve trains. Start/Stop technology. Idle shut down. No starters. Instant run. Rear mounted ISG “integrated starter/generator” Multiple batteries or new battery technology.

Disappearing drive belts…. Disappearing drive belts will reduce drag on engine, resulting in improved emissions.

Electromagnetic Valve solenoids. This is a biggie ! Obviously no cam shaft drag as well as no timing chain or belt worries, but also no more valve timing issue. The PCM will now be able to precisely control spark timing and advance. This will have a dramatic improvement on emissions and horsepower !

Liquid cooled alternators and ISG’s ? You bet ! These new devices can be belt driven, mounted to the driveline in the rear of the crankshaft or on the front of the crankshaft by the balancer. They will get Hot! Air cooling or liquid (coolant) cooling will need to be done. This will dramatically improve heating systems.

What do these new ISG’s look like ?

Vistean unit This unit can produce up to 12kW.

Siemens Unit Can be used to drive the vehicle in boost mode. Up to 15 kW can be achieved.

Sach’s dyna start Stator and Rotor are connected to crankshaft.

Start & Stop technology. (WOW) These new systems can now have the vehicle shut off at idle conditions. This will greatly improve emissions. When the light turns green and you step on the gas you will accelerate with the same ease as always, except with less driveline twist ! Less u-joints and mount jobs.

Instant run technology. When we typically start a conventional vehicle we are dealing with around cranking rpm. This requires us to add a great deal of fuel to the mixture and deal with retarded timing performance and emissions concerns. These new systems will instantly spin at speeds of RPM, thus improving performance and emissions. These systems can even be used to help propel the vehicle !

The first systems will be dual voltage systems. The early systems will be dual voltage. They will use 42 volts to start and charge the battery {S}. Most other devices will still use 14 volt technology. You will need to attend classes to be able to diagnose these and the new 42 volt systems.

Inverters for the early systems. These devices will get hot ! They will most likely fail. This is what the vehicle will use to achieve the dual voltage ability.

What about batteries ? This is the tough issue. Car manufactures are having trouble making an affordable and dependable battery. The early systems will use conventional batteries either a 12 and 24 volt pair or 3, 12 volt batteries in series.

New battery technology Lithium batteries show some promise. General Motors will use a new glass mat battery. (2001 corvette) This battery can be mounted in any position except upside down.

New battery technology These new batteries are fully recombinant. This allows the electrolyte to be absorbed into the glass fiber mats surrounding each plate. Each plate –glass electrolyte package is a sealed unit. The glass mats also help almost all the Hydrogen and Oxygen created by the battery to recombine into water instead of escaping as a gas. As the battery charges it is converted back to H and C.

Balancer Remember, the harmonic balancer will most likely be removed with these new systems.

Typical vehicle schematic

Equipment needs…. $$$$$$$ You will most likely need to either update your current tools with software. If your existing equipment is too old to be updated then replacement will be necessary. Battery/load testers Scanners Etc.

Thank YOU AST wishes to thank each and everyone in attendance tonight. We hope you have enjoyed this presentation and that you will let us know if we can be of any further assistance to you in the future. John Forro