Voltage Regulator Airflow Slots for Alternator Thermal Management
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Solution Overview
Problem
Existing voltage regulator devices for rotating electrical machines, such as alternators in motor vehicles, face operational inefficiencies and temperature-related issues when exposed to severe conditions, particularly high temperatures, due to inadequate heat dissipation and compact design requirements.
Innovation Solution
The introduction of a voltage regulator device with a support structure featuring air circulation slots and a heat sink with angled wings to enhance heat dissipation, allowing air to flow through the brush holder and direct it towards a depression zone, thereby reducing the temperature of the electronic circuit and improving the operation of the brushes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the voltage regulator device is positioned close to the heat engine to meet compactness requirements, then the device compactness is improved, but the temperature of the electronic circuit increases
Solution Approach 1:
The support structure is divided into a first part for mounting electronic components and a second part for accommodating the brush holder, with air circulation slots separating them. This segmentation allows different thermal management strategies for each section while maintaining overall device compactness.
Solution Approach 2:
Air circulation slots are introduced to create a airflow path through the support structure. The airflow carries heat away from the brush holder and electronic circuit, using pneumatic principles to achieve thermal management without additional active cooling components.
2Device complexity
If traditional brush holder design is used without air circulation, then the device structure is simple, but the brush operation deteriorates under high temperature conditions
Solution Approach 1:
The support structure is segmented into distinct regions with air circulation slots separating the brush holder area from the electronic circuit area. This segmentation enables independent thermal management of the brush holder, improving brush reliability without complicating the overall structure.
Solution Approach 2:
The air circulation slots enable the brush holder to self-cool through natural or forced airflow. The structure itself provides the cooling function without requiring external active cooling systems, maintaining simplicity while improving reliability.
3Loss of energy
If air circulation slots are added to the support structure, then the heat dissipation is improved, but the support structure becomes more complex
Solution Approach 1:
The air circulation slots are integrated directly into the support structure as part of the mounting plate design. This merging of cooling function into the structural component achieves heat dissipation without adding separate cooling devices or significantly increasing structural complexity.
Solution Approach 2:
The support structure serves multiple functions: mechanical mounting of electronic components, accommodation of brush holder, and heat dissipation through air circulation slots. This multi-functionality reduces the need for additional components, balancing heat dissipation improvement with structural simplicity.
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 improves heat dissipation, reduces the temperature of the electronic circuit, and enhances the reliability and performance of the voltage regulator device, even under severe temperature conditions, without requiring additional parts or modifications to existing systems.
Implementation Method 1
The device is configured to allow air circulation through said first part of the support, in contact with said brush holder
Implementation Method 2
the device further comprising one or more slots, called air circulation slots, said slots being provided through the support between said first part and said brush holder
Implementation Method 3
the said support being provided capable of being mounted on the electrical machine of so that the heatsink can direct a flow of air towards a depression zone provided between said regulator device and said machine
Data Source
AI summary
The invention relates to a voltage regulator device for a rotary electric machine, notably an alternator and/or an alternator/starter of a motor vehicle, said regulator device (14) comprising a support (34) and one or more electronic components (28) able to play a part in controlling said electric machine, the support comprising a first part (60) on which the component or components is or are mounted, said first part having an edge (62) equipped with a brush holder (50) equipped with at least one housing, known as the brush housing, capable of housing a brush (15) for making an electrical connection with a rotor (3) of the electric machine possible. According to the invention, said device is configured to allow air to flow through said first part of the support, in contact with said brush holder. The invention also relates to an assembly of a device for rectifying the current produced by the electric machine and of such a regulator device, to a bearing of an electric machine equipped with such an assembly and to an electric machine equipped with such a bearing.