Brushless Alternator Claw Pole Rotor Cooling and Current Optimization
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Solution Overview
Problem
Brushless alternators with claw pole rotors have limited output current due to increased demagnetizing reactions, insufficient cooling, and inefficiencies caused by complex designs, leading to reduced application time and efficiency.
Innovation Solution
The alternator design includes a rotatable drive shaft with stationary claw poles, multiple three-phase windings, mirror-image rotor and excitation sets, reduced claw pole width ratio, improved cooling through vent-holes and radiators, and phase displacement of windings to enhance current distribution and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If claw pole width ratio (maximal to minimal) is increased, then magnetic flux density is improved, but iron losses in stator pack increase and efficiency decreases
Solution Approach 1:
The patent optimizes the claw pole width ratio by changing the geometric parameters of the rotor structure. Specifically, it establishes that the ratio of maximal width to minimal width of claw poles should be within 1.8-2.5, which balances magnetic flux density enhancement with iron loss reduction, thereby improving overall efficiency
2Power
If demagnetizing reaction of stator winding is increased, then output current is limited, but this is caused by concentrated execution of stator winding
Solution Approach 1:
The patent segments the stator winding into multiple distributed windings arranged in parallel, rather than using a single concentrated winding. This segmentation reduces the demagnetizing reaction by distributing the magnetic flux paths, thereby enabling higher output current capability
3Duration of action of stationary object
If cooling system is simplified, then design complexity is reduced, but application time is shortened due to insufficient cooling
Solution Approach 1:
The patent integrates the cooling system with existing structural components of the alternator, making the cooling function universal rather than adding separate dedicated cooling components. The cooling channels are formed within the housing and end bells that already exist for structural support, achieving efficient cooling without increasing overall design complexity
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 increases output current, reduces temperature rise, and prolongs alternator and bearing application time while maintaining constant volume and drive shaft speed, achieving higher efficiency and reduced iron losses.
Implementation Method 1
To the drive shaft before the front end bell and outside of the housing cooling fan is assembled
Implementation Method 2
The stator consists of cylindrical stator pack with multiple axial slots formed on its inner surface where a three-phase stator winding is situated
Implementation Method 3
improved cooling through vent-holes and radiators
Data Source
AI summary
It is designed for accumulator batteries charging and for electrical energy generating with rectified voltage for movable and unmovable vehicles and/or objects.It possesses two identical mirror-image disposed rotor 2 and 2a and excitation 3 and 3a sets and common stator 4 with three-phase stator winding 11 realized in two groups windings, dephasing on 60/q electrical degrees. Each winding 11 is switched on with own terminals and diodes to rectified block 26, build of group isolated 30 and group connected with chassis ground 31 diodes upset in two metal, ribbed, concentric situated inner 32 and outside 33 radiators pressed with their plane surfaces to rear end bell 7 of housing 5. Inner radiator 33 has ventilation holes 35. Advantage of alternator is increased output current at reduced input power and constant alternator volume and speed of rotation as well as increased applied time of alternator and its bearings.