Generator Rectifier Assembly Spring Strip Biasing
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Solution Overview
Problem
Existing rectifier assemblies for generators are difficult to assemble due to complex configurations and alignment requirements, which can lead to misalignment and inefficiencies in the conversion of AC voltage to DC voltage for main field windings.
Innovation Solution
A rectifier assembly design featuring a first and second housing with spring strips that bias diodes against electrical rings, and connection terminals with screw-threaded areas to secure bolts, simplifying the assembly process by maintaining spring strip position and orientation, and reducing the need for additional fastening components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional rectifier assembly configurations are used, then the rectifier can perform AC to DC conversion, but the assembly process becomes difficult due to complex configurations and alignment requirements
Solution Approach 1:
The rectifier assembly is divided into modular components including a first housing containing rectifier elements and a second housing containing connection terminals, allowing independent assembly and alignment along an assembly axis. This segmentation enables simpler manufacturing of individual modules while maintaining overall functionality.
Solution Approach 2:
The spring strip and diode are combined into a single integrated component where the spring strip serves both as a mechanical support structure and as an electrical conductor. This merging reduces the number of separate parts that need to be aligned and assembled, directly addressing the assembly difficulty.
2Manufacturing precision
If traditional rectifier assembly configurations are used, then the rectifier can perform AC to DC conversion, but misalignment occurs during assembly leading to inefficiencies
Solution Approach 1:
The spring strip is configured with a transverse portion extending perpendicular to the assembly axis, providing alignment features in a different dimensional plane. This transverse orientation creates natural alignment references that guide proper positioning during assembly, improving alignment precision without complicating the assembly process.
Solution Approach 2:
The spring strip's elastic properties enable it to self-align with the electrical rings during assembly. The spring's natural tendency to return to its equilibrium position provides self-correcting alignment forces, ensuring proper positioning without requiring complex external alignment tools or procedures.
3Reliability
If additional fastening components are used to secure spring strips, then the connection becomes more secure, but the assembly process becomes more complex
Solution Approach 1:
The spring strip functions as a flexible elastic element that provides both mechanical support and electrical connection. Its elasticity allows it to maintain reliable contact with the electrical rings through continuous pressure, eliminating the need for additional rigid fastening components while ensuring secure connection.
Solution Approach 2:
The spring strip's elastic properties enable it to self-align with the electrical rings during assembly. The spring's natural tendency to return to its equilibrium position provides self-correcting alignment forces, ensuring proper positioning without requiring complex external alignment tools or procedures.
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 assembly efficiency and reliability of the rectifier assembly, ensuring proper alignment and operation, thereby improving the conversion of AC to DC voltage for generators, facilitating easier maintenance and reducing the risk of misalignment during assembly.
Implementation Method 1
At least one spring strip includes a first spring strip portion transverse to a second spring strip portion, the second spring strip portion to bias diodes against an inner periphery of the pair of electrical rings
Data Source
AI summary
A rectifier assembly according to an example of the present disclosure includes, among other things, a first housing and a second housing extending along an assembly axis, the first housing surrounding a pair of electrical rings. At least one spring strip includes a first spring strip portion transverse to a second spring strip portion, the second spring strip portion to bias diodes against an inner periphery of the pair of electrical rings. The second housing includes at least one connection terminal for receiving a wire from an exciter rotor, the at least one connection terminal including a screw threaded area which receives a bolt holding the first spring strip portion. A generator and a method of assembling a rectifier assembly are also disclosed.