Alternator Rotor Insulating Support with Plug-in Diode Assembly
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Solution Overview
Problem
The assembly and maintenance of electronic circuits in alternators are complex due to the need for multiple components and long disconnection times for diodes, which are components with limited current capacity, requiring intervention in connections for replacement or testing.
Innovation Solution
The alternator rotor features a support made of insulating plastic with fast-on type plugs for electronic components, allowing rapid assembly and secure connection of diode bridges, which can be easily removed and replaced without needing to disconnect connections, using conductive tracks and threaded studs for secure locking and overmoulding for mechanical fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If traditional assembly methods with multiple components and fasteners are used, then the rectifier structure is stable and secure, but the disassembly and maintenance time is long and complex
Solution Approach 1:
The patent integrates multiple components (diodes, supports, fasteners, insulators, conductors) into a single integrated rectifier assembly where the housing contains all elements in a unified structure, allowing the entire assembly to be replaced as one unit rather than disassembling individual components
Solution Approach 2:
The rectifier is designed as a separable module that can be independently removed from the alternator system, enabling quick replacement without disturbing other components of the alternator
2Reliability
If diodes are firmly fixed with multiple fasteners, then the connection is secure and reliable, but the disconnection process is time-consuming and complex
Solution Approach 1:
Multiple fastening functions are combined into a single housing structure that provides both mechanical support and electrical insulation, eliminating the need for separate fasteners and insulators
Solution Approach 2:
The traditional mechanical fastening system with multiple fasteners is replaced by a integrated housing design that uses the housing itself as the fastening and insulation mechanism
Data Source
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AI summary
Alternator rotor, comprising: a set of polar wheel field windings, an exciting armature, and an electronic power supply circuit supplying power to the set of polar wheel field windings from the exciting armature, the rotor being characterized in that the electronic power supply circuit comprises a bearing made of insulating material and conducting tracks held by said bearing, these tracks connecting the exciting conductors to terminals into which electronic components of the electronic power supply circuit are plugged and locked mechanically in place.