Adaptable Electric Motor Linkage for Gearbox-Free EV Weight Reduction
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Solution Overview
Problem
Electric motors and propulsion elements in electric vehicles contribute significantly to the vehicle's size, weight, and cost, particularly in urban mobility vehicles, due to their large size and the presence of components like gearboxes that consume valuable space and generate performance losses.
Innovation Solution
Adaptable electric motors with a stator unit comprising a plurality of winding elements connected by dynamic mechanical linkage systems, including ball joints and scissor mechanisms, allowing for adjustable circumferential length and shape, eliminating the need for a gearbox by using a rotor unit with shuttles to directly drive the wheel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional electric motors with gearboxes are used, then propulsion power is sufficient, but vehicle weight increases significantly and cabin space is reduced
Solution Approach 1:
The stator is divided into multiple modular segments that can be independently positioned and configured. Each segment contains winding elements that can be selectively activated, allowing the motor to maintain sufficient propulsion power while using fewer physical components, thereby reducing overall weight.
Solution Approach 2:
The motor employs dynamic mechanical linkage systems with ball joints and scissor mechanisms that allow the stator segments to be repositioned in real-time. This dynamic adaptability enables the motor to optimize its configuration for different power requirements, maintaining full propulsion capability while minimizing weight through selective segment activation.
2Power
If traditional electric motors with gearboxes are used, then propulsion power is sufficient, but cabin space and real estate are consumed
Solution Approach 1:
By segmenting the stator into modular units, the motor achieves the same propulsion power with a more compact overall footprint. The segmented design allows for optimized spatial arrangement, reducing the space required in the cabin while maintaining full power output capability.
Solution Approach 2:
The dynamic mechanical linkage system serves multiple functions: it enables stator segment repositioning for power optimization, facilitates compact packaging for space efficiency, and allows adaptive configuration for different operating conditions. This multi-functionality eliminates the need for separate gearbox components, freeing up cabin space.
3Power
If traditional electric motors with gearboxes are used, then propulsion power is sufficient, but device complexity and cost increase
Solution Approach 1:
The invention merges the functions of the gearbox and the motor into a single integrated unit. The dynamic mechanical linkage system that enables stator segment repositioning also serves as the speed and torque multiplication mechanism, eliminating the need for a separate gearbox and reducing overall system complexity.
Solution Approach 2:
The dynamic mechanical linkage system with ball joints and scissor mechanisms serves dual purposes: it enables adaptive stator configuration for power optimization and simultaneously provides the gear ratio changes traditionally handled by a separate gearbox. This multi-functionality reduces component count and simplifies the propulsion system architecture.
4Weight of moving object
If adaptable stator configuration is implemented, then vehicle weight is reduced and space is optimized, but manufacturing complexity increases
Solution Approach 1:
The stator is divided into standardized modular segments that can be manufactured independently using conventional manufacturing processes. Each segment is a self-contained unit with standardized interfaces, allowing for simplified production, quality control, and assembly, thereby mitigating the manufacturing complexity introduced by the segmented design.
Solution Approach 2:
The dynamic mechanical linkage systems use standardized ball joints and scissor mechanisms that are well-established in mechanical engineering. These components can be manufactured using conventional processes and assembled through standardized procedures, reducing the manufacturing complexity despite the dynamic reconfiguration capability.
Data Source
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AI summary
An electric motor can comprise a stator unit comprising a plurality of winding elements, wherein each pair of consecutive winding elements of the plurality of winding elements can be coupled by a dynamic mechanical linkage system comprising a first set of ball joints, a second set of ball joints and a scissor mechanism coupling the first set of ball joints and the second set of ball joints. The electric motor can further comprise a rotor unit comprising at least one shuttle that can be magnetically coupled to the plurality of winding elements and mechanically coupled to a rail structure of the stator unit, wherein the at least one shuttle can follow a circumferential length of the stator unit, such that a circumferential length of the electric motor can be altered according to a circumferential length of the stator unit.