Rotary Machine Voltage Regulator Heat Sink Design
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Solution Overview
Problem
Existing voltage regulator devices for motor vehicle alternators face challenges in efficiently dissipating heat at high temperatures, particularly above 120°C, due to their compact design and proximity to the thermal engine, leading to reduced efficiency and reliability.
Innovation Solution
A voltage regulator device with a heat sink featuring parallel heat-dissipating vanes that can orient air flow towards a region of depression between the support and the machine, enhancing airflow trajectory and effectiveness, and additional features such as a copper heat sink and brush holder design to improve cooling, allowing the device to function reliably up to 225°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the voltage regulator device is positioned close to the thermal engine for compactness, then the device can be integrated more efficiently, but the temperature increases above 120°C reducing reliability
Solution Approach 1:
A heat sink is introduced as an intermediary component between the electronic circuit and the high-temperature environment. The heat sink absorbs heat from the electronic components and dissipates it to the surrounding air, acting as a thermal mediator that protects the electronic circuit from excessive temperatures while allowing the device to remain compact and close to the thermal engine.
Solution Approach 2:
The heat sink changes the thermal parameters of the system by providing a dedicated heat dissipation path. It transforms the thermal management approach from passive (relying on natural convection) to active (using extended surface area through vanes to enhance heat transfer), allowing the electronic circuit to operate at lower temperatures even when positioned near the thermal engine.
2Loss of energy
If a heat sink is added to evacuate heat, then heat dissipation capacity is improved, but the device complexity increases
Solution Approach 1:
The heat sink is merged with the support structure that holds the electronic circuit. By integrating the heat dissipation function into the existing support component, the design avoids adding separate, complex cooling systems. The support structure serves dual purposes: mechanical support and heat dissipation, thereby improving heat evacuation without significantly increasing device complexity.
Solution Approach 2:
The support structure is designed to perform multiple functions: it provides mechanical support for the electronic circuit and simultaneously serves as a heat sink with heat-dissipating vanes. This multi-functionality eliminates the need for separate cooling components, maintaining structural simplicity while achieving effective heat dissipation.
3Volume of moving object
If the electronic circuit is located in a compact space near the thermal engine, then space utilization is improved, but heat evacuation becomes difficult
Solution Approach 1:
The heat sink extends the heat dissipation surface into the third dimension by adding vertical vanes that protrude from the support structure. This dimensional extension creates additional surface area for heat transfer to the surrounding air, enabling effective heat evacuation from the compact space where the electronic circuit is located near the thermal engine.
Solution Approach 2:
The heat sink surface is segmented into multiple parallel vanes rather than a single solid block. This segmentation increases the surface area available for heat dissipation and allows air to circulate between the vanes, improving convective heat transfer. The segmented structure enables efficient heat evacuation from the compact electronic circuit while maintaining a space-efficient design.
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
The solution significantly enhances heat dissipation and cooling efficiency, making the voltage regulator device more robust and responsive to temperature increases, ensuring reliable operation even at severe temperature conditions.
Implementation Method 1
a heat sink having parallel heat-dissipating vanes, said heat sink being in a heat-exchange relationship with said component or components... the vanes of the heat sink can orient an air flow towards a region of depression
Implementation Method 2
said heat sink being in a heat-exchange relationship with said component or components... more effective heat exchange is obtained
Data Source
AI summary
A voltage regulator device for a rotary electrical machine, notably an alternator and/or alternator-starter of a motor vehicle. The regulator device (14) comprises one or more electronic components (28) able to contribute to controlling the electric machine, a heat sink (30) having parallel heat-dissipating vanes (32). The heat sink is in a heat-exchange relationship with the component or components, and a support (34) on which the heat sink is positioned. The support is able to be mounted on the electric machine in such a way that the vanes of the heat sink can orient an air flow towards a region of depression provided between the support and the machine. A bearing of an electric machine is equipped with such a device and to an electric machine equipped with such a bearing.