Alternator Diode Interconnection for Cooling and Stress
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Solution Overview
Problem
Existing alternator designs face challenges in managing tensile and compressive stresses in diode head wires and connectors, leading to potential damage and inefficiencies in air flow and cooling, particularly due to the arrangement of half-arms and connecting sections.
Innovation Solution
The design incorporates half-arms arranged adjacent to each other with twisted upper edges to reduce stress and enhance air flow, using a U-shaped cooling body and bearing shield to house connecting sections, and a T-shaped orientation of half-arms and connecting sections to facilitate efficient air flow and reduce pressure loading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If the half-arms are arranged directly adjacent to one another before the connecting sections, then a low flow resistance is attained and air throughflow is increased, but excessive tensile or compressive stresses occur in diode head wires or diode connectors
Solution Approach 1:
The interconnection element is divided into two half-arms that are arranged adjacent to each other before the connecting sections. This segmentation allows the air flow to pass between the half-arms, reducing flow resistance, while the connecting sections maintain structural integrity and prevent excessive stress on diode components.
Solution Approach 2:
The connecting sections act as intermediaries between the half-arms and the diode connectors. These connecting sections absorb and distribute mechanical stresses, preventing excessive tensile or compressive loads from being transmitted directly to the diode head wires and connectors, while still allowing the half-arms to be positioned for optimal air flow.
2Strength
If the half-arms are twisted relative to one another, then the connection between interconnection element and insulator is strengthened, but excessive tensile or pressure loading occurs between half-arm and diode connector
Solution Approach 1:
The connecting sections are designed with cushioning characteristics that absorb and distribute mechanical loads before they reach the diode connectors. This beforehand cushioning prevents excessive tensile or pressure loading on the diode connectors while still allowing the half-arms to be twisted for enhanced connection strength between the interconnection element and insulator.
3Volume of moving object
If the connecting sections are arranged to provide phase signal to controller, then a space-saving arrangement is attained, but the complexity of housing both connecting section and cooling body increases
Solution Approach 1:
The housing structure merges the cooling body and the bearing shield into a single integrated component. The connecting section that provides phase signal to the controller is housed within this merged structure, specifically in the region between the cooling body and bearing shield. This integration achieves space-saving arrangement while managing the complexity through functional consolidation.
Solution Approach 2:
The merged housing structure serves multiple functions: it provides cooling through the cooling body, supports the bearing shield, and houses the connecting section for phase signal transmission. This multi-functionality reduces the need for separate components and achieves space-saving arrangement without proportionally increasing complexity.
4Weight of stationary object
If the half-arms and connecting sections form a T-shape, then expedient flow conditions are achieved, but the manufacturing complexity of bending multiple components increases
Solution Approach 1:
The interconnection element is designed as a single piece with half-arms and connecting sections that are bent into the T-shape configuration. This merging of components into a single bent piece simplifies manufacturing compared to assembling multiple separate components, while still achieving the expedient flow conditions required for optimal air flow through the machine.
Data Source
AI summary
The invention relates to an electric machine (10) which is embodied as an alternator, comprising a rotor (20) and an axis of rotation (183), a stator iron (17) which maintains a stator winding (18). Said stator winding (18) comprises phase terminals of winding wires (204), a rectifier circuit (151) which comprises at least one bridge circuit consisting of a positive diode (99) and a negative diode (58). Said positive diode (99) and the negative diode (58) are connected in an electrically conductive manner to the phase terminal of winding wires (204) by means of a metal connecting element (133, 146) which has two half arms (215). One half arm (215) is connected in an electrically conductive manner to a positive diode (99) by means of a connecting section (216) and another half arm (215) is connected in an electrically conductive manner to the negative diode (58) by means of another connecting section. The half arms (215) are oriented in front of the connecting sections (216) in such a manner that the metal surfaces (240) are oriented perpendicular to a rotational axis (183) of the rotor (20). The half arms (215) are arranged parallel to each other on a longitudinal section in front of the connecting sections (216). Said connecting sections (216) start respectively from a half arm (215) and comprise ends (217) which are aligned counter to each other.