Alternator B+ Connection Resistance Reduction

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Solution Overview

Problem

Modern automotive alternators face efficiency limitations due to electrical resistances in the B+ connections, which contribute to electrical losses and thermal limitations in the rectifier circuit, especially with increasing electrical demands in hybrid and electric vehicles.

Innovation Solution

The alternator system employs a copper bus conductor with bent portions surrounding rectifier B+ terminals, shaped into a ring terminal, and secured with a stop, such as a nut, to minimize connection resistance by maximizing contact surface area and direct contact between the bus conductor and the B+ stud.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional B+ connection structures are used, then the alternator structure is simple, but the connection resistance is high causing electrical losses and thermal limitations

Engineering Contradiction:

Improveelectrical losses in B+ connectionVSAvoidcomplexity of B+ connection structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The B+ connection is divided into multiple contact interfaces: rectifier B+ terminals, bus conductor contact surfaces, and B+ stud contact surfaces. Each interface is optimized independently with bent portions of the bus conductor surrounding each rectifier terminal to create multiple parallel current paths, reducing overall connection resistance through distributed contact points rather than a single connection point.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bus conductor is formed with bent portions that extend in multiple spatial dimensions around the rectifier B+ terminals. This three-dimensional configuration increases the contact surface area from a simple linear connection to a multi-faceted surround contact, creating numerous parallel current paths and significantly reducing connection resistance.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Productivity

If the B+ connection resistance is reduced, then alternator efficiency is improved, but the manufacturing complexity increases

Engineering Contradiction:

Improvealternator efficiencyVSAvoidease of manufacturing B+ connection

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The bus conductor is formed as a single integrated piece that combines multiple functions: it connects all rectifier B+ terminals, provides structural support, and creates optimized current paths. The bent portions are formed as one continuous structure rather than separate components, simplifying assembly while achieving reduced connection resistance through the integrated multi-contact design.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple contact points are used in B+ connection, then connection resistance is reduced, but the contact surface area requirement increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidcontact surface area of bus conductor

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The bus conductor is formed with bent portions that curve around the rectifier B+ terminals, creating rounded contact surfaces that conform to the terminal geometry. This curved configuration maximizes the contact surface area at each interface while maintaining a compact overall structure, increasing the number of effective contact points without proportionally increasing the total material volume.

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 configuration significantly reduces B+ connection resistance by up to 64% compared to conventional systems, enhancing overall alternator efficiency and reducing thermal limitations.

Implementation Method 1

coupling the B+ terminals and the B+ stud together with a copper bus conductor

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

bending a copper bus conductor so that one side of the bus conductor surrounds and abuts each of the rectifier B+ terminals

Methodology Applied

Scientific EffectElectrical contact: Conduction (electrical)

Data Source

PatentUS9154022B2High efficiency B+ connection

Publication Date: 2015.10.06 PHINIA TECHNOLOGIES INC

AI summary

An alternator includes a B+ bolt, rectifier B+ terminals, a bus having bends respectively surrounding ones of the rectifier B+ terminals and having an end formed into a ring terminal, and a stop, where the bus ring terminal is placed onto the B+ bolt and a load cable ring terminal may be placed onto the B+ bolt in direct contact with the bus ring terminal and secured thereto by the stop. A method of connecting B+ on an alternator includes bending a copper bus conductor so that one side of the bus conductor surrounds and abuts each of the rectifier B+ terminals, shaping one end of the bus conductor into a ring terminal, and placing the ring terminal of the bus conductor onto the B+ stud. A method includes coupling the B+ terminals and the B+ stud together with a copper bus conductor, and cooling the copper bus conductor.