ELECTRIC MACHINE FOR A MOTOR VEHICLE

The electric machine addresses torque limitations by employing a variable air gap design between laminated rotor and stator cores, optimizing operation and torque output through adjustable core diameters, thus enhancing performance and efficiency.

DE102024102766A1Pending Publication Date: 2025-07-31BAYERISCHE MOTOREN WERKE AG
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Patent Information

Application Number
DE102024102766
Authority / Receiving Office
DE · DE
Patent Type
Applications
Current Assignee / Owner
Filing Date
2024-01-31
Publication Date
2025-07-31

AI Technical Summary

Technical Problem

Existing electric machines in motor vehicles face challenges in achieving maximum torque due to variations in the air gap diameter caused by factors like rotor expansion, centrifugal forces, and temperature-induced expansions, leading to a design compromise that enlarges the air gap beyond the optimal magnetic point of view.

Method used

The electric machine features a rotor and stator laminated core with a variable air gap designed in a step-like manner along the axial direction, allowing for a minimal and uniform air gap during operation by adjusting the distance between the cores to accommodate rotor bulging and temperature-induced expansions.

Benefits of technology

This design enables the electric machine to operate with a minimal and uniform air gap, thereby achieving maximum torque and reducing discrepancies, while maintaining simplicity in production through the use of laminated core sections with varying diameters.

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Abstract

An electric machine (1) for a motor vehicle is provided, wherein the electric machine (1) comprises a rotor (20) having a rotor lamination stack (22), and a stator (10) having a stator lamination stack (12). The stator lamination stack (12) surrounds the rotor lamination stack (22) at a distance. A distance (A) between the stator lamination stack (12) and the rotor lamination stack (22) varies in a step-like manner along an axial direction (R) of the rotor (20).
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Claims

[1] Electric machine (1) for a motor vehicle, the electric machine (1) comprising: - a rotor (20) having a rotor core (22), and - a stator (10) having a stator laminated core (12), wherein the stator laminated core (12) surrounds the rotor laminated core (22) at a distance, characterized by that a distance (A) between the stator laminated core (12) and the rotor laminated core (22) varies in steps along an axial direction (R) of the rotor (20). [2] Electrical machine (1) according to claim 1, characterized by that the distance (A) in a central region (A3) along the axial direction (R) is greater than in outer regions (A1, A5) along the axial direction (R) and / or the distance (A) increases in steps in the direction of the central region (A3). [3] Electrical machine (1) according to claim 2, characterized bythat the distance (A) in the middle area (A3) is at least twice as large as in the outer areas (A1, A5). [4] Electrical machine (1) according to claim 2 or 3, characterized by that the distance (A) is selected such that the distance (A) approaches during operation of the electrical machine (1) due to an occurring centrifugal force along the axial direction (R) and varies by less than 50% during operation. [5] Electrical machine (1) according to one of claims 1 to 4, characterized by that the distance (A) along the axial direction (R) is always less than 1 mm. [6] Electrical machine (1) according to one of claims 1 to 5, characterized by in that the rotor laminated core (20) is divided into rotor laminated core sections (22.1 - 22.6) which are arranged next to one another in the axial direction (R), wherein the rotor laminated core sections (22.1 - 22.6) have at least partially different outer diameters. [7] Electrical machine (1) according to claim 6, characterized by that the stator laminated core (10) has a constant inner diameter. [8] Electrical machine (1) according to one of claims 1 to 6, characterized by in that the stator laminated core (10) is divided into stator laminated core sections (12.1 - 12.5) which are arranged next to one another in the axial direction (R), wherein the stator laminated core sections (12.1 - 12.5) have at least partially different inner diameters. [9] Electrical machine (1) according to claim 8, when dependent on one of claims 1 to 5, characterized by that the rotor core (20) has a constant outer diameter. [10] Motor vehicle, characterized by that the motor vehicle comprises the electric machine (1) according to claim 9.

Citation Information

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