Generator Voltage Controller Redundancy
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Solution Overview
Problem
Existing alternator voltage regulators face the risk of excessive output voltage when one control unit fails, leading to potential damage in the vehicle electrical system, and require additional connections and complexity for reliable regulation.
Innovation Solution
A voltage regulator with two independent control units, where the second control unit takes over if the first fails, using excitation voltage as a manipulated variable to control the alternator output, allowing for redundant operation and reduced complexity without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single control unit is used to regulate alternator output voltage, then the device complexity is low, but the reliability deteriorates when the control unit fails causing excessive voltage
Solution Approach 1:
The voltage regulator is divided into two independent control units: a first control unit that regulates voltage under normal conditions, and a second control unit that activates when the first fails. This segmentation allows each unit to be simpler while collectively providing high reliability through redundancy.
Solution Approach 2:
The second control unit is designed as a backup that activates beforehand when voltage exceeds a second threshold, preventing damage from excessive voltage. This cushioning approach ensures that even if the first control unit fails, the system maintains safety margins before critical damage occurs.
2Reliability
If additional connections and components are added to detect control unit defects, then the reliability improves, but the device complexity and costs increase
Solution Approach 1:
The second control unit monitors voltage levels and automatically detects when the first control unit fails by observing when voltage continuously exceeds the second threshold. This self-service approach eliminates the need for separate defect detection circuits or additional sensors, maintaining simplicity while ensuring reliability.
Solution Approach 2:
The second control unit uses feedback from the alternator output voltage to determine when the first control unit is malfunctioning. When voltage remains above the second threshold despite regulation attempts, the second unit infers first unit failure and takes over control, providing automatic defect detection without additional hardware.
3Speed
If a second control unit with higher threshold is added for rapid voltage reduction, then the response speed to voltage spikes improves, but the device complexity increases
Solution Approach 1:
The control system is segmented into two units with different response thresholds: the first control unit handles normal voltage regulation, while the second control unit with a higher threshold provides rapid response to severe overvoltage conditions. This segmentation allows optimized response speeds for different scenarios without requiring a single complex controller.
Solution Approach 2:
The second control unit is designed to activate only in extreme cases when voltage exceeds the second threshold, providing excessive action only when necessary. This partial activation approach maintains simplicity by keeping the second unit dormant during normal operation, engaging only when rapid voltage reduction is critically needed.
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
Ensures the alternator output voltage remains within safe limits even if one control unit fails, preventing damage and maintaining reliable regulation without additional components or complexity.
Implementation Method 1
The alternator converts mechanical energy, which is supplied via a pulley from the vehicle's drive engine, into electrical energy.
Implementation Method 2
the first control unit and the second control unit are designed to influence an excitation voltage of an excitation winding of the alternator
Data Source
Figure 1~2
AI summary
The invention relates to a voltage controller (1) of a generator (2), comprising a first control unit (3) and a second control unit (4), which is independent of the first control unit (3), the first control unit (3) being designed to lower an output voltage of the generator (2) when a first maximum value (100) is exceeded, and the second control unit (4) being designed to lower the output voltage either when a first maximum value (100) is exceeded or when a second maximum value (200) different from the first maximum value (100) is exceeded.