Diode Mounting Ring With Contact Bands Instead of Braze Joints

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Solution Overview

Problem

Traditional diode mounting rings in rotating rectifier assemblies for generators face issues with material weakness due to braze joints and health hazards from Beryllium Copper (BeCu) usage, necessitating improved mounting methods that enhance durability and safety.

Innovation Solution

The use of Aluminum mounting rings with interference fit, spring-type contact bands, and absence of BeCu, allowing for secure DC pin mounting without braze joints, and incorporating axial and circumferential coolant channels for improved thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional brazed pins are used in mounting rings, then DC connections are established, but the braze joints weaken the material and reduce reliability

Engineering Contradiction:

Improvemounting ring strengthVSAvoidmaterial strength at braze joints

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent removes the braze joints from the mounting ring assembly entirely. Instead of brazing DC pins to the mounting ring, the invention uses press-fit interference connections and spring-type contact bands that eliminate the need for brazing, thereby eliminating the weakness introduced by braze joints while maintaining electrical connectivity.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the thermal joining process (brazing) with mechanical joining methods. Specifically, it uses interference fits and spring-type contact bands with contactless gaps to establish DC connections, substituting the mechanical-brazing system with a purely mechanical system that avoids the material weakening associated with braze joints.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If Beryllium Copper (BeCu) is used for mounting rings, then good conductivity is achieved, but health hazards are created during machining

Engineering Contradiction:

Improveelectrical conductivityVSAvoidhealth hazards from BeCu machining

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent substitutes the expensive and hazardous Beryllium Copper material with a safer, more cost-effective alternative. The mounting ring is made from materials that do not pose health hazards during machining, eliminating the need for special handling and safety precautions while maintaining the necessary electrical conductivity for the application.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent converts the harmful aspect of BeCu (health hazards during machining) into a benefit by selecting materials that are safer to machine. The new material selection eliminates health risks while maintaining or improving other properties such as cost-effectiveness and manufacturability, turning a harmful material choice into a beneficial one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If traditional mounting methods are used, then DC pins are connected, but assembly complexity and manufacturing costs increase

Engineering Contradiction:

ImproveDC connection reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into integrated components. The spring-type contact bands serve both as electrical connectors and as mechanical retention elements, eliminating the need for separate fasteners or complex assembly steps. This merging of functions reduces assembly complexity while maintaining reliable DC connections.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spring-type contact bands provide self-retaining functionality through their elastic properties. When the DC pins are inserted, the spring bands automatically engage and retain them through contactless gaps, eliminating the need for additional fastening operations or complex assembly procedures. The system serves itself by using the elastic deformation of the spring bands to secure the connections.

Inventive Principle:

Principle #25Self-service

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 solution reduces assembly complexity, manufacturing costs, and enhances conductivity and cooling efficiency while eliminating health hazards associated with BeCu, resulting in a more reliable and cost-effective mounting system for rotating rectifier assemblies.

Implementation Method 1

The contact bands can be spring type contact bands

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

each respective joining interface of the at least one contact bands can be an interference fit

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS11799391B2Diode mounting ring with contact band inserts

Publication Date: 2023.10.24 HAMILTON SUNDSTRAND CORP

AI summary

An assembly comprises a mounting ring for a rotating rectifier assembly (RRA) having a pin bore defined in the mounting ring oriented in an axial direction and at least one contact band seated in a the pin bore of the mounting ring for mounting a direct current (DC) pin to the mounting ring. A method comprises forming a mounting ring for a rotating rectifier assembly (RRA), including forming a pin bore in the mounting ring oriented in an axial direction, and installing at least one contact band into a the pin bore of the mounting ring.