Alternator system
AssigneeUnit Parts Company
InventorsMichael D. Ballard, Jianing Chen, Daniel Joseph Clark, Larry Joe Maddox
Life of this patent
Estimating the term…
Abstract
An improved alternator system for replacing an OEM Ford IAR alternator system. The improved alternator system includes a rectifier with increased heat dissipation qualities and decreased heat generation qualities and configured to maintain secure electrical connections. The alternator system is further configured to provide optimum electrical output by providing the rotor and the stator with additional turns or windings of heavier gauge wire whereby the alternator is capable of inducing a stabilized output current of at least about 52 amperes of current at about 1600 revolutions per minute of the rotor.
Claims21
A rectifier in combination with a Ford IAR alternator which is of the type having a rotor coil and a plurality of stator windings housed in a frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator, the rectifier comprising:
- a first plate defining a negative heat sink, the negative heat sink having a plurality of diode receiving openings formed therein;
- a second plate defining a positive heat sink, the positive heat sink electrically insulated from the negative heat sink and having a plurality of diode receiving openings formed therein;
- a plurality of negative diodes press fit into the openings of the negative heat sink;
- a plurality of positive diodes press fit into the openings of the positive heat sink, each of the positive diodes corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings;
- and
- a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having a first end secured to the connector box, a medial portion electrically connected to the positive heat sink, and a second end, and a terminal having a first end electrically connected to the B+ post and a second end including a pair of prongs disposed in the recess of the frame.
A rectifier in combination with a Ford IAR alternator which is of the type having a rotor coil and a plurality of stator windings housed in a frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator, the rectifier comprising:
- a first plate defining a negative heat sink, the negative heat sink having a plurality of diode receiving openings formed therein and having a thickness greater than about 5 mm;
- a second plate defining a positive heat sink, the positive heat sink having a plurality of diode receiving openings formed therein and having a thickness greater than about 5 mm;
- an insulator positioned between the positive heat sink and the negative heat sink so as to electrically insulate the positive heat sink from the negative heat sink, the insulator having a thickness less than about 0.020 mm;
- a plurality of negative diodes press fit into the openings of the negative heat sink;
- a plurality of positive diodes press fit into the openings of the positive heat sink, each of the positive diodes corresponding with and electrically coupled to one of the negative diodes and electrically connected to one of the stator windings;
- and
- a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, a B+ post having a first end secured to the connector box, a medial portion electrically connected to the positive heat sink, and a second end, and a terminal having a first end electrically connected to the B+ post and a second end including a pair of prongs disposed in the recess of the frame, the B+ post having a minimum diameter of about five millimeters.
In a Ford IAR alternator of the type having a rotor coil and a plurality of stator windings housed in a frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which a rectifier is mounted and electrically connected to the stator, the rectifier having a connector assembly including a connector box having a recess adapted to matingly receive a wiring harness, the improvement comprising:
- a tab formed on an outer surface of the connector box, the tab having a slot formed therethrough;
- and
- means for engaging a portion of the rectifier and a portion of the wiring harness so as to maintain the wiring harness in operable engagement with the rectifier.
In a Ford IAR alternator of the type having a rotor coil and a plurality of stator windings housed in a frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and an internal mounting surface to which the rectifier is mounted and electrically connected to the stator, the improvement comprising:
- a rotor coil disposed in the alternator interior space of the housing and rotatably supported by the housing, the rotor coil having a plurality of wire windings wound thereabout, the wire windings of the rotor coil having an electrical current flowing therethrough for generating a rotating magnetic field as the rotor coil rotates;
- means for selectively rotating the rotor coil at a speed of at least 1600 revolutions per minute;
- a stator positioned in the rotating magnetic field generated by the rotor coil and supported by the housing, the stator having a first side, a second side and a plurality of slots formed between the first side of the stator and the second side of the stator;
- a plurality of stator windings wound through the slots of the stator in a predetermined manner to form an output of the replacement alternator whereby the rotating magnetic field induces an electrical current in the stator windings;
- and
- means for inducing a sufficient amount of current in the stator windings at about 1600 revolutions per minute of the rotor coil to provide a stabilized current output of at least about 52 amperes.
In a method for sensing the voltage output of a Ford IAR alternator of the type having a rotor coil and a plurality of stator windings housed in a frame having an external mounting surface to which a voltage regulator is mounted and electrically connected to the rotor and to a battery and an internal mounting surface to which a rectifier having a positive heat sink is mounted and electrically connected to the stator and to the battery whereby the voltage regulator receives signals indicative of the alternator voltage output voltage via the battery, the improvement comprising the steps of:
- providing the voltage regulator with a B+ terminal;
- extending a post from the positive heat sink of the rectifier and through the frame of the alternator;
- and
- attaching a lead between the B+ terminal of the voltage regulator and the terminal post so as to establish electrical communication between the positive heat sink of the rectifier and the B+ terminal of the voltage regulator whereby the voltage regulator receives signals indicative of the voltage output of the alternator directly via the positive heat sink of the rectifier.
Dependencies are inferred from the claim text.