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Analytical and experimental studies were conducted to determine means to decrease the temperature rise in the rectifier and rear housing of a small-frame alternator. An interactive computer program based on finite difference, ITAS (Interactive Thermal Analysis Systems), was used to analytically determine the temperature field of the alternator. The analytical results (including steady-state energy balance) were then used to guide the experimental effort, Best performance was achieved with a modified system design which included changes in the air flow path, finning the rectifier directly, and using an improved fan. This resulted in a temperature drop of 30 deg F over the entire operating range for the 40-amp modified alternator compared to the original design.

To address the need of increasing fuel economy requirements, automotive Original Equipment Manufacturers (OEMs) are increasing the number of turbocharged engines in their powertrain line-ups. The turbine-driven technology uses a forced induction device, which increases engine performance by increasing the density of the air charge being drawn into the cylinder. Denser air allows more fuel to be introduced into the combustion chamber, thus increasing engine performance. During the inlet air compression process, the air is heated to temperatures that can result in pre-ignition resulting and reduced engine functionality. The introduction of the charge air cooler (CAC) is therefore, necessary to extract heat created during the compression process. The present research describes the physics and develops the optimized simulation method that defines the process and gives insight into the development of CACs.