Axially Stacked Rotor Cores with Protruding Teeth for BSG Torque
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Solution Overview
Problem
The existing belt-driven starter generators (BSG) face limitations in torque increase due to spatial constraints and current limits, and the manufacturing process is complicated by the need for separate members to secure winding spaces, leading to increased costs and time.
Innovation Solution
A rotor design featuring axially stacked first and second rotor cores with protruding teeth and insulators that abut each other to close winding spaces, eliminating the need for separate cover members and allowing wider coil spaces for improved torque and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the number of wound coils is increased to increase torque, then torque increases, but spatial constraints limit the number of coils that can be accommodated
Solution Approach 1:
The rotor core is divided into multiple segments with teeth, creating multiple separate winding spaces. This segmentation allows coils to be distributed across multiple teeth and winding spaces, effectively increasing the total coil capacity and torque output without exceeding the overall spatial constraints of the rotor assembly.
Solution Approach 2:
The invention utilizes the axial dimension by stacking multiple rotor cores with teeth arranged in different axial positions. This three-dimensional arrangement of winding spaces allows for increased coil capacity by exploiting the axial direction, thereby increasing torque without proportionally increasing the radial or circumferential dimensions.
2Reliability
If a separate member is added to close the winding space after coil winding, then coil deviation is prevented, but manufacturing time and costs increase
Solution Approach 1:
The winding spaces are pre-formed by the tooth structures of the rotor cores before the coil winding process. The teeth naturally define the boundaries of the winding spaces, eliminating the need for additional closing members. This preliminary structuring of the winding spaces ensures coil positioning accuracy while reducing manufacturing steps and time.
Solution Approach 2:
The invention removes the separate closing member from the design by utilizing the tooth structures themselves to define and contain the winding spaces. This extraction of the unnecessary component simplifies the manufacturing process, reduces assembly steps, and lowers costs while maintaining reliable coil positioning.
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 design enhances torque by increasing the coil space factor, simplifies the winding process, and reduces manufacturing time and costs by eliminating the need for additional components to secure winding spaces.
Implementation Method 1
a vehicle includes a starter motor which drives an engine and an alternator which generates electricity using a rotational force of the engine
Data Source
AI summary
A rotor may include a first rotor core and a second rotor core. The first rotor core includes a first core body and a first teeth protruding from an outer circumferential surface of the first core body. and the second rotor core includes a second core body and a second teeth protruding from an outer circumferential surface of the second core body. Each of the first teeth includes a first extension protruding axially in a first direction, and each of the second teeth includes a second extension protruding axially in a second direction opposite the first direction. The first extension includes a first protrusion provided on a first inner circumferential surface of the first extension, and the second extension includes a second protrusion provided on a second inner circumferential surface of the second extension.