Compact Coil Bobbin Design for Brushless Alternator Airflow
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Solution Overview
Problem
Existing coil bobbin configurations in brushless alternators are not compact enough for large-scale industrial usage and do not allow sufficient airflow or space for electronic components, limiting their performance and compatibility with existing mounting methods.
Innovation Solution
A compact coil bobbin design with an integrally formed one-piece body featuring a coil support portion, a base portion, and a bobbin extension portion of varying diameters, which allows for increased airflow and space for electronics, and includes a flange base and alignment ring for proper mounting and centering within the alternator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a traditional coil bobbin configuration is used, then the alternator structure is simple, but the device is not compact enough and does not allow sufficient airflow or space for electronic components
Solution Approach 1:
The coil bobbin is divided into three distinct functional segments: a coil support portion with flanges for mounting, a bobbin extension portion with smaller diameter for electronics mounting, and a base portion with flange segments. This segmentation allows each portion to serve its specific function while achieving overall compactness and accommodating electronic components.
Solution Approach 2:
The bobbin extension portion extends axially between the coil support and base portions, utilizing the axial dimension to create space for electronic components without increasing the radial footprint. This dimensional approach maintains compactness while providing necessary mounting space.
2Adaptability or versatility
If the coil support portion is positioned at the first end with flanges, then mounting compatibility is achieved, but space for electronic components is reduced
Solution Approach 1:
The bobbin is segmented into distinct functional zones: the coil support portion with flanges at one end for mounting compatibility, and the bobbin extension portion with smaller diameter at the other end for electronics mounting. This segmentation allows both mounting compatibility and electronics space to coexist.
Solution Approach 2:
Different portions of the bobbin have different diameters and structures optimized for their specific functions: the coil support portion has larger diameter with flanges for mounting, while the bobbin extension portion has smaller diameter for electronics, creating local quality variations that satisfy both requirements.
3Object-affected harmful factors
If the bobbin extension portion has smaller diameter, then airflow is improved, but structural strength may be reduced
Solution Approach 1:
The bobbin extension portion has smaller diameter specifically where airflow is needed, while the coil support portion and base portion maintain larger diameters for structural strength. This local quality variation optimizes both airflow and strength in different locations.
Solution Approach 2:
The bobbin is segmented into portions with different diameters: the coil support portion and base portion provide structural strength, while the intermediate bobbin extension portion has smaller diameter to facilitate airflow, with each segment optimized for its specific requirement.
4Adaptability or versatility
If the base portion is segmented into flange segments, then adaptability to housing configurations is improved, but manufacturing complexity increases
Solution Approach 1:
The base portion is segmented into multiple flange segments that can be arranged in different configurations to adapt to various housing openings, while still being manufacturable as an integrated portion of the bobbin structure.
Solution Approach 2:
The segmented flange base portion provides universal adaptability to different housing configurations and mounting arrangements, allowing the same bobbin design to fit various alternator housing types by adjusting flange segment arrangements.
Data Source
AI summary
A coil bobbin for a brushless alternator includes an integrally formed one piece bobbin body that has a first end, a second end and a central passage that extends from the first end to the second end. A coil support portion of the body is positioned at the first end and has a first cylinder of a first diameter bordered by flanges which extend past the first cylinder. A base portion of the body is positioned at the second end. A bobbin extension portion is positioned between the coil support portion and the base portion. The bobbin extension portion includes a second cylinder of a second diameter which is smaller than the first diameter.