AC Generator Voltage Regulator Insert Conductor Jumper Integration
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Solution Overview
Problem
The manufacturing of vehicle AC generators faces challenges in cost reduction due to the need for diverse voltage regulation device specifications, which often requires additional components like jumpers for circuit connections, increasing production complexity and costs.
Innovation Solution
An AC generator design with a molded body and insert conductors that include an extended-portion-for-jumper, allowing for direct electrical connection using identical welding equipment, eliminating the need for separate jumpers and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate jumpers are provided to connect terminals for different circuit configurations, then adaptability to various specifications is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The insert conductor is designed to serve multiple functions: it acts as both a standard terminal connection point and an extended jumper connection point. By integrating the jumper functionality directly into the insert conductor structure, the same component can accommodate different circuit configurations without requiring separate jumper components, thereby reducing device complexity while maintaining adaptability to various specifications
Solution Approach 2:
The invention merges the function of separate jumpers into the insert conductor itself. The extended portion of the insert conductor that protrudes from the molded body serves as an integrated jumper, eliminating the need for separate jumper components. This consolidation reduces the total number of parts and simplifies the overall device structure while preserving the ability to create different circuit configurations
2Adaptability or versatility
If separate jumpers and additional components are used for different circuit configurations, then adaptability is improved, but manufacturing cost increases
Solution Approach 1:
The insert conductor is designed as a universal component that can serve multiple circuit configurations through its extended portion. This multi-functionality eliminates the need to manufacture and inventory separate jumper components for different specifications, reducing manufacturing costs through economies of scale while maintaining adaptability to various circuit requirements
Solution Approach 2:
The invention extracts the jumper functionality from separate components and integrates it directly into the insert conductor. By taking out the jumper function and embedding it in the mold during insert conductor formation, the manufacturing process is simplified and component count is reduced, leading to lower manufacturing costs while preserving configuration flexibility
3Adaptability or versatility
If jumpers are provided as separate components for circuit connections, then circuit configuration flexibility is improved, but the number of components increases
Solution Approach 1:
The invention combines the jumper function with the insert conductor into a single integrated component. The extended portion of the insert conductor that protrudes from the molded body serves as the jumper, eliminating the need for separate jumper components. This merging reduces the total number of components while maintaining circuit configuration flexibility through the integrated design
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 reduces manufacturing and device costs by enabling the use of the same welding equipment for various circuit configurations, eliminating the need for additional components and simplifying the production process.
Implementation Method 1
a rectification device for converting the AC electromotive force into DC output voltage
Implementation Method 2
a voltage regulation device for regulating the magnitude of the output voltage
Data Source
AI summary
To provide an AC generator equipped with a voltage regulation device capable of cost reduction in terms of both of manufacture and device, a voltage regulation device for the AC generator, and a method for manufacturing the same. In an AC generator equipped with a voltage regulation device 16 for regulating the magnitude of output voltage, the voltage regulation device 16 is composed of: a molded body 15 having a plurality of insert conductors; and a circuit component 14 mounted on the molded body 15 and electrically connected to the insert conductors, and in the voltage regulation device 16, an extended-portion-for-jumper 19ae is integrally provided in a part of the insert conductor 19a.