Alternator Regulator Power Stage With Redundant Transistor Control
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Solution Overview
Problem
Existing electronic devices such as variators and regulators are limited by size constraints, reliability issues under extreme conditions, and manufacturing costs, particularly when used in critical applications like power supply for hospitals or nuclear reactors, where component failure can be catastrophic.
Innovation Solution
The design incorporates a power stage with power components mounted on a heat sink and capacitors extending through openings, featuring a recessed seal for efficient cooling and compactness, along with a housing that allows for easy assembly and attachment to a support, and includes redundancy in power transistors for enhanced reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power components are mounted on a heat sink and capacitors are arranged vertically through openings, then the device size is reduced, but the manufacturing complexity increases
Solution Approach 1:
The device is divided into distinct functional modules: power components mounted on a heat sink, capacitors arranged vertically through openings, and a control circuit board. This segmentation allows each module to be manufactured and assembled separately, reducing overall manufacturing complexity while maintaining compact dimensions.
Solution Approach 2:
Capacitors are arranged vertically through openings in the heat sink, utilizing the vertical dimension rather than horizontal space. This dimensional change reduces the device's footprint while accommodating all necessary components within a compact volume.
2Temperature
If power components are mounted on a heat sink, then cooling efficiency is improved, but the device size increases
Solution Approach 1:
The heat sink is integrated with the capacitor mounting structure, combining thermal management and component support functions into a single structure. This merging eliminates the need for separate cooling components, improving cooling efficiency while maintaining compact device size.
Solution Approach 2:
The heat sink serves multiple functions: it provides thermal management for power components, acts as a structural support for vertically mounted capacitors, and serves as part of the device housing. This multi-functionality reduces the overall device size while maintaining effective cooling.
3Reliability
If redundancy is added to power transistors, then reliability is improved, but the device complexity increases
Solution Approach 1:
Redundant power transistors are pre-installed in the circuit configuration, providing failover capability before any failure occurs. This beforehand cushioning ensures that if one transistor fails, the redundant unit can immediately take over, maintaining operational reliability without requiring complex real-time monitoring or switching mechanisms.
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 compactness and reliability of the device while maintaining industrial manufacturing costs, ensuring efficient cooling and reduced risk of component breakage, thus improving operational resilience under extreme conditions.
Implementation Method 1
at least one power component mounted on a heat sink
Implementation Method 2
efficient cooling of the power component
Data Source
Figure 1~12
Figure 2
Figure 3
AI summary
An electronic device, in particular an alternator regulator, comprising a power stage to be connected to an inductive load (L), in particular an alternator inductor, comprising at least one first pair of power transistors (TH1, TH2) connected to a terminal of a DC bus (+), and a control circuit (240) for these transistors, the transistors being arranged in parallel between said DC bus terminal and a first output (230) to be connected to the load, at least one flyback diode (DL1, DL2) connecting the opposite terminal of the DC bus to the first output, the control circuit being designed to generate a pulsed control signal (241) for regulating the current in the load and for detecting a failure of one of the transistors, the control circuit being designed, during normal operation, in the absence of a failure of the transistors, for sending a control signal to one of the transistors (TH1) of the first pair, while maintaining the other transistor (TH2) of this pair in a blocked state.