Vehicle AC Generator Component Sharing Molded Body
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Solution Overview
Problem
Vehicle AC generators without a regulator cannot share components with those that have a voltage-regulating device, leading to increased fabrication costs and complexity due to the need for separate components and molding dies.
Innovation Solution
The AC generator design includes a molded body with a capacitor and resistor connected to an insert conductor, allowing for shared components and the use of the same molding die for both configurations, with the capacitor connected only when the device main body is inside the generator and the resistor connected only when it is outside.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the same holder is used for both generator types and the device main body is removed, then component sharing is achieved, but the heat sink is also removed and the resin cannot be sealed
Solution Approach 1:
The holder is divided into two functional parts: the base holder structure that remains common to both generator types, and the removable heat sink that is specifically attached only when the device main body is installed. This segmentation allows the holder to adapt to different configurations while maintaining proper resin sealing in each case.
Solution Approach 2:
The heat sink is designed as a dynamic component that can be attached or removed based on the installation configuration. When the device main body is installed, the heat sink is attached to provide heat dissipation and serve as a resin-receiving cover. When the device main body is removed, the heat sink is detached, and a different sealing mechanism is employed. This dynamic adaptability resolves the contradiction between component sharing and resin sealing reliability.
2Ease of manufacture
If the heat sink is used only for receiving resin, then cost and component count are reduced, but this is not accepted and common use of components is hindered
Solution Approach 1:
The heat sink is designed to perform multiple functions: heat dissipation when the device main body is installed, and serving as a resin-receiving cover when the device main body is not installed. By making the heat sink multi-functional rather than single-purpose, the invention achieves both cost reduction through component sharing and maintained adaptability across different generator configurations.
3Manufacturing precision
If separate components and molding dies are used for generators with and without regulators, then each configuration can be optimized, but fabrication cost and complexity increase
Solution Approach 1:
The holder is designed as a universal component that can accommodate both generator configurations with and without the device main body. The same holder structure and molding die are used in both cases, with the only difference being the presence or absence of the removable heat sink. This universality maintains manufacturing precision while significantly reducing fabrication complexity and cost.
Solution Approach 2:
The configurable nature of the heat sink attachment allows the same holder to adapt to different generator types. The molding die remains the same, but the final configuration can be dynamically adjusted by attaching or removing the heat sink based on whether the device main body is installed, thereby optimizing for each configuration without requiring separate manufacturing processes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enables significant reduction in fabrication costs by allowing the same components to be used for both types of generators, improving workability and reliability through direct welding, and maintaining heat dissipation performance.
Implementation Method 1
a rotor around which a rotor winding is wound, for inducing an AC electromotive force in the stator winding by rotational driving thereof
Implementation Method 2
a heat sink bonded to a heat-generating portion of the device main body through a thermally-conductive member
Data Source
AI summary
Provided is a vehicle AC generator which enables the common use of components and the use of the same molding die for molded bodies to enable a significant reduction in fabrication cost. The vehicle AC generator includes a molded body (45). On one surface side of the molded body, a capacitor body (43) including a capacitor element built therein is electrically connected to an insert conductor. On another surface side of the molded body, a resistor (44) is electrically connected to the insert conductor only when a device main body is provided outside of the AC generator, and the device main body is electrically connected to the insert conductor only when the device main body is provided in the AC generator.