Segmented Engine Bracket for Alternator Mounting Safety
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Solution Overview
Problem
Existing methods for mounting auxiliary components like alternators on internal combustion engines are unsafe and inefficient, requiring operators to manually pivot and hold the components against gravity while aligning and tightening bolts, which can be hazardous and time-consuming.
Innovation Solution
A vehicle engine mounting system featuring upper and lower brackets with semi-circular grooves and shaft-wise openings, allowing operators to securely support the weight of the component with one bracket while inserting and tightening bolts with the other, eliminating the need to hold the component in place during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a horizontal groove bracket design is used to support the alternator weight, then the alternator can be positioned and supported, but the operator must manually pivot and hold the alternator against gravity while aligning and tightening bolts, creating safety hazards and increasing installation time
Solution Approach 1:
The mounting bracket is divided into two separate functional components: an upper bracket with a groove for supporting the alternator weight, and a lower bracket with a through-hole for bolt passage. This segmentation allows the weight support function and the fastening function to be performed independently, eliminating the need for operators to simultaneously hold the alternator and manipulate bolts.
Solution Approach 2:
The upper bracket acts as an intermediary that temporarily supports the alternator weight during installation. By providing this intermediate support structure, the system allows operators to work on bolt installation without directly bearing the alternator weight, thereby improving safety and ease of operation.
2Strength
If the fixing portion is located in a vertical direction against gravity below the horizontal groove, then the alternator can be secured, but operators must manipulate the alternator against gravity with one hand while manipulating bolts with the other hand
Solution Approach 1:
The alternator is first positioned and supported by the upper bracket groove before bolt installation begins. This preliminary positioning action secures the alternator in place, allowing subsequent bolt installation to proceed without requiring continuous manual support, thereby reducing installation time.
Solution Approach 2:
The mounting process transitions from a static manual holding position to a dynamic installation sequence where the alternator is temporarily supported by the upper bracket, then secured by bolts through the lower bracket. This dynamic approach optimizes both safety and efficiency throughout the installation process.
3Reliability
If two brackets are used to position the alternator, then the alternator can be securely mounted, but operators must simultaneously lift/hold the component and insert/tighten bolts, which is hazardous and time-consuming
Solution Approach 1:
The mounting system is segmented into an upper bracket for weight support and a lower bracket for fastening. This segmentation separates the weight-bearing function from the fastening function, allowing operators to work efficiently without simultaneously performing both tasks, thereby improving productivity while maintaining mounting security.
Data Source
AI summary
Methods and systems are provided for a bracket and surrounding structure for mounting a front end accessory drive component, such as an alternator, to an engine. Hanging heavy components on brackets may be dangerous and difficult for human operators as well as violate assembly standards. To securely hold the component to the engine in order to withstand vibrations and to protect the operator, an open bracket with a curved lip and surrounding support structure is used to mount the component to the engine.