Electronic Module Power Connections Outside Diameter
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Solution Overview
Problem
Existing solutions for rotary electrical machines, such as alternator starters, are bulky and costly due to bulky cables and have issues with power interconnection tracks that overheat due to insufficient cross-sections, making them inefficient for high current applications.
Innovation Solution
An electronic module with a housing that positions power connections close to the machine's outside diameter, allowing for larger conductors and easier integration, using power connections that are directly attached to the module and connected via a coaxial plane independent of the module's space, enabling parallel supply and reduced heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If power connections are positioned inside the peripheral band with the electronic components, then integration is improved, but the conductor cross-section is reduced causing excessive heating
Solution Approach 1:
The power connections are moved from the radial dimension (inside the peripheral band) to the axial dimension (at the outside diameter), utilizing the axial space above the electronic components. This dimensional change allows for larger conductor cross-sections without increasing the radial footprint, thereby reducing heating while maintaining integration.
2Reliability
If a three-phase connecting cable is used to connect the electronic box to the rotary electrical machine, then electrical connection is achieved, but the device becomes bulky and expensive
Solution Approach 1:
The bulky three-phase connecting cable is extracted and replaced with integrated power connections that are directly formed as part of the electronic module structure. The power connections extend axially from the electronic components at the outside diameter, eliminating the need for separate external cables and reducing overall device complexity.
3Area of stationary object
If power interconnection tracks with small cross-sections are used on the bearing, then space is saved, but the tracks reach excessively high temperatures due to insufficient current capacity
Solution Approach 1:
The power connections are repositioned from the radial plane (on the bearing surface) to the axial dimension (at the outside diameter above the bearing). This allows the conductors to have larger cross-sections in the axial direction without occupying additional radial space, thereby increasing current capacity and reducing track temperature while maintaining compactness.
Data Source
AI summary
An electronic module for a rotary electrical machine which applies to any type of polyphase rotary electrical machine, synchronous or asynchronous, such as alternators or alternator starters, and also whether it is a case of electrical machines for motor vehicles and driven for example by belt, with cooling by air, liquid or any other solution that can be envisaged.