Rotating Electrical Machine Regulator Partition Member Design
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Solution Overview
Problem
In conventional regulators for vehicle AC power generators, unforeseen electrical short circuits can occur due to scattered molten metal or pressing residue during welding, and conductive foreign matter can stick to the insert terminal, leading to reliability issues and increased risk of short circuits, especially when the regulator holder is filled with insulating resin.
Innovation Solution
A rotary electric machine design that incorporates a partition member with insert portions between connection terminals and main body terminals, which pushes out conductive foreign matter and prevents short circuits, improving reliability by ensuring electrical insulation and secure attachment of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection terminals are connected to main body connection portions by welding within the narrow space inside the regulator holder, then electrical connection is achieved, but conductive foreign matter such as spatter or pressing residue may cause unforeseen electrical short circuits
Solution Approach 1:
The regulator holder is divided into multiple compartments by partition walls, separating connection terminals from each other and from the interior space. This segmentation prevents conductive foreign matter from moving between terminals and causing short circuits, while still allowing welding connections to be made within isolated chambers.
Solution Approach 2:
Partition walls act as intermediary structures between connection terminals and the interior space of the regulator holder. These walls provide physical barriers that prevent direct contact between conductive foreign matter and electrical connections, eliminating the harmful effect while maintaining the necessary electrical connections.
2Reliability
If the regulator holder is filled with insulating resin material, then connection portions are protected, but conductive foreign matter may move with the resin material due to filling pressure, increasing the likelihood of electrical short circuits
Solution Approach 1:
By dividing the regulator holder into compartments using partition walls, the invention prevents conductive foreign matter from moving freely throughout the entire interior space when resin material is injected. The segmentation creates isolated chambers where foreign matter cannot travel between terminals, even under resin filling pressure.
Solution Approach 2:
The partition walls are installed before the resin filling process to preemptively block the movement paths of conductive foreign matter. This preliminary protective measure ensures that even when resin material exerts pressure during filling, the foreign matter cannot migrate to critical electrical connection areas.
3Reliability
If air blowing removal measures are adopted to remove conductive foreign matter, then some foreign matter is removed, but it is difficult to remove foreign matter completely from the interior space of the regulator holder
Solution Approach 1:
The partition wall structure creates isolated compartments that contain any remaining conductive foreign matter in non-critical areas. Even if air blowing cannot completely remove all foreign matter, the segmentation ensures that any residual contamination is confined away from electrical connections, achieving practical complete protection.
Data Source
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AI summary
In a rotary electric machine, a regulator that regulates an AC voltage generated in a stator coil includes a regulator holder, a regulator main body, and a partition member having an electrical insulating property. The regulator holder includes a molded member and a plurality of main body terminals provided on the molded member. The regulator main body includes a main body portion that includes an IC chip and is provided on the molded member, and a plurality of connection terminals that project from the main body portion and are connected individually to the respective main body terminals. The partition member includes an insert portion that is inserted into a gap between respective connection portions by which the main body terminals are connected to the connection terminals.