Rectifier Vibration Resistance via Heatsink Reinforcement
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Solution Overview
Problem
Automotive AC generators face challenges with increased vibration loads on rectifying elements due to higher output power requirements, leading to potential damage and reduced lifespan, as well as issues with current density and leakage currents.
Innovation Solution
A rectifier design with a high-side heatsink and terminal block assembly that includes a reinforcing member to increase rigidity near the output terminal, and a direct fixation mechanism for terminal blocks to match vibration phases, reducing cyclic vibration loads on rectifying elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the output power of AC generator is increased to meet higher electric load requirements, then the power output is improved, but the vibration load on rectifying elements increases causing potential damage and reduced lifespan
Solution Approach 1:
The patent applies local quality by making the heatsink portion adjacent to the output terminal thicker than other portions. This localized structural enhancement provides additional rigidity and vibration resistance specifically where needed - at the location experiencing highest vibration loads from the output terminal - without increasing the overall weight or complexity of the entire heatsink structure.
Solution Approach 2:
The patent implements beforehand cushioning by pre-reinforcing the heatsink structure at the vulnerable location adjacent to the output terminal before vibration damage can occur. The increased thickness at this location acts as a preventive measure, cushioning the rectifying elements against vibration-induced stress and potential failure during operation.
2Manufacturing precision
If the diameter of output line is increased to suppress current density, then the current density is reduced, but the weight of output line increases
Solution Approach 1:
The patent applies parameter changes by modifying the heatsink structure (increasing thickness at specific portions) rather than changing the output line dimensions. This alternative approach addresses vibration-related reliability issues without requiring an increase in output line diameter, thereby avoiding the associated weight increase while still achieving the goal of improving system reliability.
3Reliability
If the diameter of bolt and size of bolt thread are increased to increase clamping force, then the electrical connection reliability is improved, but the vibration load on heatsink increases causing deformation and rectifying element damage
Solution Approach 1:
The patent applies local quality by selectively increasing the thickness of the heatsink at the portion adjacent to the output terminal, where vibration loads are highest. This localized reinforcement provides the necessary structural strength to withstand vibration forces from larger bolts without requiring an increase in bolt size, thereby maintaining electrical connection reliability while protecting against heatsink deformation.
4Reliability
If the thickness of heatsink portion adjacent to output terminal is increased to reduce vibration load on rectifying elements, then the rectifying element durability is improved, but the device complexity increases
Solution Approach 1:
The patent minimizes device complexity by applying local quality - making only the specific portion of the heatsink adjacent to the output terminal thicker. This targeted approach provides the necessary vibration resistance and rectifying element protection without requiring a complete redesign or uniform thickening of the entire heatsink structure, thus avoiding significant increases in manufacturing complexity.
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 design enhances the durability and lifespan of rectifying elements by minimizing deformation and vibration-induced damage, maintaining reliable electrical connections and reducing leakage currents.
Implementation Method 1
a reinforcing member mounted on a portion of the high-side heatsink close to the output terminal and working to increase rigidity of the portion of the high-side heatsink close to the output terminal
Implementation Method 2
The plurality of pairs of high-side and low-side rectifying elements work to rectify alternating-current power to direct-current power
Implementation Method 3
a high-side heatsink in which the high-side rectifying elements are mounted
Data Source
AI summary
In a rectifier, a high-side heatsink in which high-side rectifying elements are mounted provides a common positive terminal attached to the high-side heatsink. A low-side heatsink in which the low-side rectifying elements are mounted provides a common negative terminal. A terminal block assembly includes a plurality of terminal blocks integrated with each other. The plurality of terminal blocks hold the conductive members. A fixing mechanism directly fixes one of the plurality of terminal blocks to the high-side heatsink. The one of the plurality of terminal blocks holds at least one of the conductive members. The at least one of the conductive members is connected to one of the high-side rectifying elements. The one of the high-side rectifying elements is located closest to the output terminal in all of the high-side rectifying elements.