Modular Alternator Coupling Flange Design
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Solution Overview
Problem
Industrial alternators face challenges in cost-effective mass production due to the need for multiple standardized diameters and varying cooling requirements, leading to increased production costs and complexity, as existing designs often require custom parts to meet different power and ventilation needs.
Innovation Solution
A modular flange design with a common rear part and adaptable front interface, allowing for different ventilation configurations and standardized interfaces, incorporating a removable fan and air deflectors to optimize airflow and reduce production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If one-piece coupling flanges are used for each standardized diameter, then the interface requirements are met, but the production quantity for each diameter is limited and mass-production means cannot be utilized
Solution Approach 1:
The coupling flange is divided into two separate parts: a common rear part that can be mass-produced and reused across different machine types, and a specific front part that interfaces with the driving engine. This segmentation allows the rear part to be manufactured in large quantities for multiple applications, enabling mass-production economics while still accommodating different interface requirements through interchangeable front parts.
Solution Approach 2:
The rear part of the coupling flange is designed as a universal component that can be used across different alternator models and power ratings. By making the rear part adaptable and interchangeable, a single design can serve multiple functions and applications, reducing the need for custom one-piece flanges for each standardized diameter and enabling broader mass-production utilization.
2Adaptability or versatility
If custom cooling means are designed for each power rating, then ventilation requirements are met, but the number of pieces increases and mass-production effect is lost
Solution Approach 1:
The cooling system is segmented into a common rear ventilation structure that can be shared across different power ratings and specific cooling outlets that can be added or configured as needed. This allows the base cooling means to be mass-produced as a standard component while accommodating different ventilation requirements through modular additions rather than designing entirely custom cooling systems for each power rating.
3Productivity
If the same cooling means/coupling flange pairing is used for all powers, then mass production is enabled, but the cooling means are overspecified for permanent use applications
Solution Approach 1:
The coupling flange design incorporates adaptable and interchangeable front parts that can be selected based on the specific power rating and application requirements. This dynamic configuration allows the system to be optimized for each application - using smaller, more efficient cooling outlets for permanent use applications with lower ventilation needs, and larger outlets for occasional use applications requiring higher cooling capacity, while still enabling mass production of the common rear structure.
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
The modular design enables cost-effective mass production by using common rear parts and adaptable front interfaces, improving airflow efficiency and reducing production costs while meeting various power and ventilation requirements.
Implementation Method 1
within which rotates a fan and which is created with air outlet grilles
Implementation Method 2
a deflector fixed on the flange, the deflector being shaped so as to guide the air flow
Data Source
AI summary
The present invention concerns an electric machine (1), in particular an alternator, intended to be coupled to a driving or driven machine, in particular a heat engine, comprising: —a coupling flange (20) for coupling to the driving or driven machine, housing a fan (30) driven by the rotor, said flange comprising: —a rear portion (21) linked to a fixed portion (10) of the electric machine, —an interfacing front portion (22) interfacing with the driving or driven machine, said interfacing front portion being mounted on the rear portion (21), the front portion (22) having a central opening, the fan having a diameter greater than that of the central opening, —at least one air deflector secured to the flange (20).