Vehicle AC Generator Component Sharing via Segmented Holder
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Solution Overview
Problem
The existing vehicle AC generators with and without regulators face challenges in sharing components and reducing fabrication costs, as the heat sink used for heat dissipation also serves as a resin-receiving cover, leading to exposed capacitor and terminal connections when trying to use a shared holder, which is not cost-effective.
Innovation Solution
The AC generator design includes a molded body with an insert conductor, where a capacitor body is connected on one surface and a resistor is connected only when the device main body is outside, and the device main body is connected on the other surface only when inside, allowing for the same components to be shared and using the same molding die, reducing fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the heat sink is removed when the device main body is removed to enable component sharing, then component versatility is improved, but the capacitor element and terminal connection portions become exposed
Solution Approach 1:
The holder is divided into two distinct parts: a heat sink portion and a resin-receiving cover portion. This segmentation allows the resin-receiving cover to remain and protect the capacitor element and terminal connections even when the device main body is removed, while still enabling component sharing between different generator types.
Solution Approach 2:
The holder is designed with multi-functionality to accommodate both generators with device main bodies and regulator-less generators. By separating the heat sink function from the resin-receiving cover function, the same holder structure can serve different purposes depending on whether a device main body is installed, enabling universality without compromising protection.
2Reliability
If a separate resin-receiving cover is added to protect exposed components, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The heat sink and resin-receiving cover are merged into a single integrated holder structure. This combining approach provides both heat dissipation and component protection functions simultaneously, avoiding the need for separate protective covers while maintaining reliability and reducing overall complexity.
Solution Approach 2:
The holder serves multiple functions: it acts as a heat sink for thermal management, a resin-receiving cover for protection and sealing, and a mounting structure for the device main body or capacitor element. This multi-functionality eliminates the need for additional separate protective components.
3Reliability
If different holders are used for generators with and without device main bodies, then component protection is ensured, but manufacturing cost and fabrication complexity increase
Solution Approach 1:
A single universal holder design is created that can accommodate both generators with device main bodies and regulator-less generators. The holder's integrated structure with separate heat sink and resin-receiving cover portions allows it to function properly in both configurations, eliminating the need for different holder types and reducing manufacturing costs.
Solution Approach 2:
The holder is segmented into functional regions (heat sink portion and resin-receiving cover portion) that can serve different purposes based on the generator type. This segmentation within a unified structure enables one holder design to replace multiple specialized holders, simplifying manufacturing.
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 the sharing of components and reduces fabrication costs by using the same molding die for both types of generators, improving workability and reliability through direct welding and efficient use of filling materials.
Implementation Method 1
a molded body 45 obtained by molding an insulating resin
Implementation Method 2
a heat sink 18, which abuts against the device main body 19 to dissipate the heat of the device main body 19
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) having the same outer shape. On one surface side of the molded body, a capacitor body including a capacitor element built therein is electrically connected to an insert conductor, and a resistor (44) is electrically connected to the insert conductor only when a device main body is provided outside of the AC generator. On another surface side of the molded body, the device main body is electrically connected to the insert conductor only when the device main body is provided in the AC generator.