AC Generator Frame Rib Reinforcement for Vibration Resistance
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Solution Overview
Problem
Conventional AC generators for vehicles experience vibration-induced elastic deformation and stress in the cooling fin, leading to distortion and adverse effects on diodes and AC terminals, while also facing challenges in maintaining high power output with small size and weight.
Innovation Solution
The AC generator incorporates a frame with reinforced end walls and fin supports to reduce elastic deformation and enhance cooling capabilities, featuring a rectifier with a U-shaped cooling fin and terminal block assembly mounted on the frame, and a stator coil with sequentially joined conductor segments for low resistance and improved power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cooling fin is mounted on the end wall with fin supports, then the rectifier can be fixed to the frame, but elastic deformation and stress occur in the cooling fin due to vibration
Solution Approach 1:
Ribs are pre-formed as integral structures with the end wall before assembly, creating a reinforced framework that proactively resists vibration-induced deformation rather than reacting to it after occurrence
Solution Approach 2:
The end wall structure combines the base wall material with additional rib reinforcements to create a composite structure with enhanced rigidity and vibration resistance while maintaining the original material properties
2Stability of the object's composition
If the frame structure is reinforced to reduce elastic deformation, then cooling fin stability improves, but device complexity increases
Solution Approach 1:
The ribs are merged with the end wall to form an integral, monolithic structure that provides reinforcement without requiring separate components, fasteners, or assembly steps, thereby maintaining manufacturing simplicity while enhancing stability
3Power
If conductor segments are sequentially joined to reduce resistance, then power output increases, but manufacturing complexity increases
Solution Approach 1:
The stator coil is divided into multiple discrete conductor segments that can be independently manufactured and then sequentially joined, allowing for optimized electrical connections that reduce resistance while maintaining manufacturing flexibility
Solution Approach 2:
Conductor segments are pre-formed with connection terminals before assembly, allowing for preliminary preparation of electrical connections that simplify the final assembly process and ensure low-resistance joints
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
The solution effectively reduces distortion and stress in the cooling fin, enhances cooling efficiency, and increases power output without increasing size or weight, ensuring stable operation and efficient heat transfer.
Implementation Method 1
a cooling fin on which the at least one rectifying element is mounted
Implementation Method 2
a cooling fin on which the at least one rectifying element is mounted
Implementation Method 3
rotating, about an axis, a magnetized rotor relative to a stator to generate AC power
Data Source
AI summary
In an alternating-current generator, an end wall of a frame is provided with a plurality of fin supports separately arranged on the outer surface of the end wall. The cooling fin is mounted on the plurality of fin supports. The end wall is provided with a plurality of reinforcements each arranged between a corresponding one of the plurality of fin supports and another one thereof and each configured to reinforce a rigidity of a portion of the end wall. The corresponding one of the plurality of fin supports and another one thereof are adjacent to each other in a circumferential direction of the axis of the rotor. The rigidity-reinforced portion of the end wall is located between the corresponding one of the plurality of fin supports and another one thereof.