Unitary Engine Mounting Bracket with Dual Cradles
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Solution Overview
Problem
Conventional engine configurations face challenges in maintaining the operating parameters of components like alternators and AC compressors within desired ranges, especially at high temperatures, while also ensuring easy servicing and not straining the engine's front housing.
Innovation Solution
A mounting structure comprising a single unitary sheet of material with specific cradles and mounting surfaces that securely positions the alternator and AC compressor, made from lightweight aluminum alloy, allowing for efficient mounting and servicing of other engine components without exposing the alternator to excessive heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the alternator is placed near the exhaust system to save mounting space, then the device complexity is reduced, but the alternator is exposed to high temperatures causing damage
Solution Approach 1:
The mounting structure is divided into separate cradles - a first cradle for the AC compressor and a second cradle for the alternator. This segmentation allows each component to be positioned independently, enabling the alternator to be mounted away from the exhaust system while the AC compressor occupies the space near the exhaust, thus resolving the conflict between space utilization and temperature exposure.
2Productivity
If multiple components are mounted on the engine, then the engine assembly becomes more compact, but servicing of individual components becomes difficult
Solution Approach 1:
The mounting bracket is designed as a multi-cradle structure where each cradle independently holds a specific component. This segmentation allows components to be mounted in a compact arrangement while maintaining individual access to each cradle, enabling easy servicing of specific components without requiring disassembly of the entire mounting structure.
Solution Approach 2:
The mounting bracket serves multiple functions simultaneously - it mounts the AC compressor, alternator, and other components, while also providing structural support and positioning. This multi-functionality allows the engine assembly to remain compact while maintaining ease of serviceability through the standardized cradle design that facilitates component removal and installation.
3Reliability
If a heavy mounting structure is used to securely position components, then the reliability of component positioning is improved, but the engine front housing experiences increased strain
Solution Approach 1:
The mounting structure utilizes the specific geometric parameters of the engine front housing - particularly the curvature matching the cradles and the positioning relative to the belt routing area. By optimizing the cradle radii and positions to match the housing geometry, the structure achieves reliable component positioning while distributing loads efficiently, preventing excessive strain on the housing despite using a substantial mounting bracket.
Data Source
AI summary
A mounting bracket includes a single unitary sheet of material, and a top portion including a first cradle including a first concave surface defining a first radius of curvature and a first longitudinal axis, and a second cradle including a second concave surface defining a second radius of curvature that is different than the first radius of curvature and a second longitudinal axis that is parallel to the first longitudinal axis. A first pair of mounting surfaces may straddle either side of the first cradle, and a second pair of mounting surfaces may straddle either side of the second cradle.