Alternator Redundant Voltage Regulator Overvoltage Protection
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Solution Overview
Problem
Conventional alternator systems face challenges in managing overvoltage failures, leading to increased power dissipation and higher costs due to the need for components that can withstand maximal overvoltage levels, which results in increased size, weight, and cost of electrical components.
Innovation Solution
The alternator system incorporates a main and redundant voltage regulator with individual controllers and power switches connected in series, allowing for automatic switching to the redundant regulator in case of overvoltage, thereby reducing the risk of overvoltage and enabling the use of less costly electrical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the alternator system is designed to limit overvoltage to a predetermined maximal level, then the reliability of electrical components is improved, but the cost and size of electrical components increase due to the need to withstand maximal overvoltage levels
Solution Approach 1:
The patent implements a redundant voltage regulator that activates before overvoltage can cause damage to electrical components. The redundant regulator serves as a protective mechanism that cushions against overvoltage failures by taking control when the main regulator fails, preventing voltage from exceeding safe levels and thereby protecting components without requiring them to be over-specified for overvoltage tolerance.
Solution Approach 2:
The redundant voltage regulator acts as an intermediary protective layer between the alternator output and the electrical components. When overvoltage occurs, the redundant regulator intervenes by limiting the voltage to a safe level, thereby mediating the harmful effect and allowing components to be designed for normal operating voltages rather than worst-case overvoltage scenarios.
2Reliability
If electrical components are designed to handle increased power dissipation at maximal overvoltage levels, then the reliability under overvoltage is improved, but the weight and size of components increase
Solution Approach 1:
The redundant voltage regulator provides beforehand protection by preventing overvoltage from reaching electrical components in the first place. This allows components to be designed for normal operating power levels rather than being oversized to handle worst-case overvoltage power dissipation, thereby reducing weight while maintaining reliability through the protective redundancy mechanism.
3Device complexity
If a single voltage regulator is used in the alternator system, then the device complexity is reduced, but the reliability under voltage regulator failure decreases
Solution Approach 1:
The voltage regulation function is segmented into two independent regulators: a main voltage regulator for normal operation and a redundant voltage regulator for backup. This segmentation allows the system to maintain simple operation during normal conditions while providing enhanced reliability through the independent backup regulator that activates upon main regulator failure.
Solution Approach 2:
The system changes the operational parameter of the redundant voltage regulator from inactive to active based on the failure state of the main regulator. During normal operation, the redundant regulator remains dormant, but upon detection of main regulator failure, the redundant regulator's parameters change to become the active voltage control mechanism, thereby maintaining system reliability.
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 enhances the robustness and reliability of the alternator system, reducing the risk of overvoltage-related failures and allowing for the use of less expensive electrical components that can operate effectively at lower voltage levels, thereby lowering overall system costs.
Implementation Method 1
an alternator with a stator having at least one stationary winding and a rotor with a rotatable field coil for producing alternating current
Data Source
AI summary
An alternator system includes an alternator with a stator having at least one stationary winding and a rotor with a rotatable field coil for producing alternating current, a main voltage regulator having a main controller and a main power switch configured to control the current through the field coil, a redundant voltage regulator having a redundant controller and a redundant power switch configured to control the current through the field coil. The main power switch, the field coil and the redundant power switch are connected in series, in that order. A power supply for an electrical system includes a battery and the alternator system. A vehicle includes the power supply.