Design and fabrication of integrated electronic power controlled alternator

Abstract

The Modern automobile industry is escalating to a higher version with a vision to minimize the power consumption of the vehicle. The government regulation is pushed hard on all fronts to bring new models to the market with efficient power utilization, emission control, safety, and design. Electrifying the vehicle is most exciting curiosity found in the young generation's meanwhile efficient management of power production and consumption required. Alternator plays a significant role in the automobile to charge the battery and to supply power to the total electrical system in the engine running condition. With years of modification of alternator followed the path from complex DC dynamo generators with commutators to simple silicon diode rectifier to fulfil the electrical system. In the present research paper an effective and efficient design of integrated motor control unit consisting of control electronic, power electronic and heat sink which is optimized as per thermal and structural aspects. The replacement of diodes with power module minimized the heat generation and power module reduced the electrical resistance flow, which helps to boost up the power generation rate. The present designed power module based alternator is made on theoretical calculation with fixed direct current 30 Amp for both diode and power module based alternator result shown a significant variation in the power loss. Power loss in case of diode 68.57W and in power module is 1W, also the heat transfer flow analysis is evaluated for both system using ANSYS 14.5.