Armature Shaft Alignment via Local Mechanical Deformation
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Solution Overview
Problem
Existing methods for aligning armature shafts in motor vehicles, such as those used in comfort drives, are costly due to the requirement of high-investment laser beam devices and result in increased operating noise from concentricity errors, which affect comfort, especially in electric vehicles.
Innovation Solution
A method using mechanical force to achieve local deformation of the armature shaft, allowing for immediate testing and alignment without the need for heating, utilizing a wedge-shaped tool and bearing element to minimize geometric impact and avoid external mechanical loads on bearing devices, with a control device adjusting force levels based on error measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If local heating of the armature shaft is performed using a laser beam device to achieve alignment, then the armature shaft can be deformed to correct concentricity errors, but the investment costs of the laser beam device are relatively high
Solution Approach 1:
The patent replaces the laser beam heating system with a purely mechanical deformation system. A deformation device applies localized mechanical force to the armature shaft to create controlled plastic deformation, eliminating the need for expensive laser equipment while achieving the same alignment correction effect.
Solution Approach 2:
The invention uses simple, inexpensive mechanical tools (deformation device with pressing element) instead of expensive, complex laser beam devices. The mechanical tool can be easily replaced or adjusted, making the overall system more cost-effective despite the tool having limited reuse life.
2Manufacturing precision
If local heating is used to deform the armature shaft for alignment, then concentricity errors can be corrected, but it is necessary to wait for the stiffening of the heated region before testing, increasing alignment time
Solution Approach 1:
By replacing thermal deformation with mechanical deformation, the patent eliminates the waiting period required for the heated region to stiffen. The mechanical deformation is immediate and stable, allowing instant testing and verification of alignment results, thus significantly reducing total alignment time.
3Manufacturing precision
If the armature shaft is plastically deformed by introducing a bending force at one end or in the middle, then alignment can be achieved, but the entire shaft portion including the output region and toothed region is mechanically stressed
Solution Approach 1:
The patent applies deformation force only at the specific location where alignment is needed, using a localized pressing element that contacts the armature shaft at a precise point. This creates localized plastic deformation without subjecting the entire shaft, including critical regions like the output region and toothed region, to unnecessary mechanical stress, thereby preserving their structural integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces alignment time and costs, minimizes concentricity errors, and allows for alignment in installed states without stressing bearing devices, ensuring armature shafts meet tolerance limits before assembly.
Implementation Method 1
the deformation is achieved by a mechanical action of force
Implementation Method 2
the armature shaft is deformed only in a very short region... by material displacement
Data Source
AI summary
A method for aligning an armature shaft, wherein in a first step a concentricity error of the armature shaft is determined in the region of the shaft portion by measuring a radial deflection of the armature shaft, and wherein in a second step the radial deflection of the armature shaft is reduced by local deformation of the shaft portion on the side of the bearing element remote from the laminated portion.