Alternator Terminal Assembly Arc Distribution
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Solution Overview
Problem
Existing alternator terminal assemblies face challenges in efficiently managing electrical connections and heat buildup due to overlapping conductive members and limited arc distribution of input connectors, which affects the overall width and performance of the alternator.
Innovation Solution
A terminal assembly with a non-electrically conductive body that houses conductive members with input connectors spread out in an arc greater than 90°, reducing radial overlaps and heat buildup, and allowing stator leads to be routed from a smaller arc to a larger arc for efficient electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conductive members are arranged in a compact configuration, then the overall width of the terminal assembly is reduced, but heat buildup increases due to overlapping conductive members
Solution Approach 1:
The patent distributes input connectors along a curved path with an arc greater than 90 degrees, transitioning from a linear or compact arrangement to a two-dimensional curved distribution. This dimensional change allows connectors to be spread out along the arc, reducing radial overlaps and heat buildup while maintaining a compact overall width by utilizing the curved space efficiently.
Solution Approach 2:
The patent employs a curved path arrangement for input connectors instead of straight lines or angular configurations. The curved geometry with arc greater than 90 degrees allows for smoother distribution of conductive members, reducing sharp overlaps and improving heat dissipation while maintaining compact dimensions.
2Temperature
If input connectors are spread out in a larger arc, then heat buildup and radial overlaps are reduced, but the complexity of routing stator leads increases
Solution Approach 1:
The patent pre-establishes a curved path template with arc greater than 90 degrees for input connector arrangement before final lead routing. This preliminary structural framework guides the routing process, allowing stator leads to be systematically routed from a smaller arc to the larger arc of the curved path, reducing routing complexity compared to ad-hoc arrangements.
Solution Approach 2:
The patent divides the terminal assembly into functional zones along the curved path, with input connectors segmented at different angular positions. This segmentation allows independent routing of stator leads to specific connector zones, simplifying the overall routing complexity by breaking down the complex connection task into manageable segments.
3Loss of substance
If conductive members are made shorter to reduce material usage, then raw material consumption is reduced, but the number of overlapping conductive members increases
Solution Approach 1:
The patent resolves the contradiction between shorter conductive members and reduced overlaps by transitioning to a curved two-dimensional arrangement. The arc greater than 90 degrees provides additional spatial dimension, allowing short conductive members to reach their targets without radial overlaps, thus maintaining low material consumption while avoiding heat buildup from overlaps.
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
This configuration minimizes the overall width of the terminal assembly, reduces heat buildup, and optimizes the use of raw materials by making conductive members shorter, while ensuring effective electrical bonding and reduced material usage.
Implementation Method 1
a body formed from a non-electrically conductive material
Implementation Method 2
a plurality of conductive members at least partially covered by the body. The plurality of conductive members is associated with the stator winding
Implementation Method 3
an alternator that transforms mechanical energy into electrical energy that is used to charge an onboard battery
Data Source
AI summary
An alternator including a housing, and a stator fixedly mounted relative to the housing. The stator includes a plurality of stator slots and a stator winding arranged in the plurality of stator slots. The stator winding includes at least five stator leads extending from five adjacent ones of the plurality of stator slots. A terminal assembly is mounted to an outer surface of the housing and is connected with at least three of the at least five stator leads. The terminal assembly includes a body formed from a non-electrically conductive material and a plurality of conductive members at least partially covered by the body. The plurality of conductive members is associated with the stator winding. Each of the plurality of conductive members includes a plurality of input connectors spread out along the body in an arc that is greater than 90°.