Single-Layer Stator Terminal Assembly for Alternator Cooling
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Solution Overview
Problem
Six-phase alternators face rectifier cooling issues due to thick dual-layer stator terminal assemblies, which also complicate and cost manufacturing, as they obstruct airflow and require individual track formation.
Innovation Solution
A single-layer stator terminal assembly with at least five electrically conductive tracks, formed from a single piece of conductive material and encapsulated in a nonconductive casing, reducing thickness and simplifying manufacturing by eliminating unnecessary electrical connections through sprue severance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dual-layer track stator terminal assembly is used to accommodate six phases with concentrated leads, then the terminal assembly can provide electrical communication between stator lead wires and rectifier bridge, but the thickness increases blocking airflow and causing rectifier cooling issues
Solution Approach 1:
The patent transitions from a dual-layer three-dimensional track arrangement to a single-layer planar configuration. By redistributing the six conductive tracks in a single layer with optimized spacing and routing, the design reduces axial thickness while maintaining all necessary electrical connections between stator leads and rectifier bridge components.
Solution Approach 2:
The terminal assembly is segmented into individual conductive track regions that are strategically positioned and spaced within a single layer. This segmentation allows each track to be optimally routed to its corresponding rectifier components without requiring vertical stacking, thereby reducing overall thickness and improving airflow.
2Reliability
If dual-layer track stator terminal assembly is used to accommodate six phases with concentrated leads, then the terminal assembly can provide electrical communication between stator lead wires and rectifier bridge, but the manufacturing complexity increases and cost increases due to need to stack individual tracks
Solution Approach 1:
The patent merges the formation of multiple conductive tracks into a single manufacturing process step. Instead of individually forming and stacking six separate tracks as in dual-layer designs, the single-layer configuration allows all tracks to be formed simultaneously in one planar layer, significantly simplifying the manufacturing process and reducing costs.
3Reliability
If dual-layer track stator terminal assembly is used to accommodate six phases with concentrated leads, then the terminal assembly can provide electrical communication between stator lead wires and rectifier bridge, but the thickness increases reducing space available for rectifier cooling fins
Solution Approach 1:
The patent reconfigures the terminal assembly from a multi-layer vertical arrangement to a single-layer horizontal arrangement. This dimensional change reduces axial thickness, thereby increasing the available volume and space for rectifier cooling fins and other cooling components within the alternator housing.
Data Source
AI summary
Disclosed is a terminal assembly for a stator of a dynamoelectric machine. The terminal assembly includes a at least five electrically conductive tracks arrayed in a single layer, each track configured and positioned for electrical communication with corresponding leads extending from the stator providing electrical connection between at least one lead of stator leads and a rectifier bridge. The tracks are at least partially encapsulated in a nonconductive casing.