Alternator Connector Angular Terminals Robotic Welding
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Solution Overview
Problem
Current connectors for rotating electrical machines, such as motor vehicle alternators, face challenges in facilitating the assembly and welding of diode tails to connection terminals due to the non-ideal placement of connection terminals, leading to increased welding time and complexity.
Innovation Solution
The connector is designed with angularly separated connection terminals, allowing electrodes of current rectifying elements to be arranged on the same arc of a circle, facilitating easier welding and assembly, particularly through robotic processes, by ensuring all contact surfaces are on the same circumference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection terminals are positioned in conventional locations in the connector, then the connector structure is simple, but the welding of diode tails to terminals becomes difficult and time-consuming
Solution Approach 1:
The connection terminals are positioned asymmetrically arranged on the connector body, specifically located on the periphery rather than in conventional central or distributed positions. This asymmetric placement allows all diode tails to be welded from the same side of the connector, dramatically simplifying the welding process while maintaining a relatively simple overall connector structure.
2Productivity
If connection terminals are arranged to facilitate robotic welding, then welding time is reduced, but the connector design becomes more complex
Solution Approach 1:
Multiple connection terminals are merged into a unified peripheral arrangement on the connector body, allowing all welding operations to be performed from the same side. This consolidation of terminal positions enables robotic welding systems to efficiently access all terminals without repositioning, significantly reducing welding time while the modular connector design keeps the overall structure manageable.
3Ease of operation
If diode tails are soldered to connection terminals with non-ideal placement, then the connector can be simpler, but assembly complexity and time increase
Solution Approach 1:
The connection terminals are given a specific local quality by positioning them all on the periphery of the connector body. This localized arrangement creates an optimal welding zone where all diode tails can be accessed and welded simultaneously from the same side, greatly improving assembly ease while the peripheral placement keeps the terminal arrangement straightforward and manageable.
Data Source
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AI summary
The invention relates to a connector for a device for rectifying the current generated by a rotary electric machine, in particular a motor vehicle alternator, said connector (8) being configured so as to establish, for each phase of the electric machine, an electrical connection between one of the phases of said electric machine and a respective arm of the rectifying device, said connector (8) including electrical conductors (40, 42, 44), each having at least two connection terminals (46) positioned angularly apart from one another, such that connection electrodes of rectifying elements of at least two of the arms of the rectifying device, which are arranged on a single arc, can contact said connection terminals (46). The invention also relates to a rectifying device provided with such a connector, and to a rotary electric machine provided with such a device.