Axle End Arrangement With Nested Rotor For Wheel Service
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Solution Overview
Problem
Existing axle end arrangements for utility vehicles are complex, difficult to mount and dismount, and require disassembly of the wheel, leading to increased maintenance and the risk of dirt and foreign bodies entering the system.
Innovation Solution
The axle end arrangement consists of a stator unit fixed to the axle stub and a rotor unit with a coil arrangement, where the rotor unit has a smaller outer radius than the vehicle wheel's fastening region, allowing the wheel to be mounted and removed without disassembling the axle end arrangement, and includes a transmission to increase power output and prevent dirt ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the axle end arrangement is designed with a compact rotor unit, then the vehicle wheel can be mounted and dismounted without disassembling the axle end arrangement, but the power output and space utilization are limited
Solution Approach 1:
The patent employs a nested structure where the rotor unit is positioned within the hub bore, and the stator unit is arranged around the rotor unit. This nesting allows the generator components to be accommodated within the limited space of the wheel hub while maintaining sufficient power output capacity. The rotor unit fits inside the hub, and the stator unit surrounds it, creating a compact nested arrangement that maximizes space utilization without compromising power generation capability.
Solution Approach 2:
The patent utilizes the axial dimension of the hub bore to accommodate the rotor unit, rather than only radial expansion. By positioning the rotor unit axially within the hub and arranging the stator unit around it in a circumferential manner, the design achieves high power density without increasing the outer dimensions that would interfere with wheel mounting. This dimensional arrangement allows the wheel to be mounted over the rotor unit while maintaining adequate power output.
2Weight of moving object
If the axle end arrangement uses a hollow axle stub to reduce weight, then the overall weight decreases, but the structural strength and rigidity may be compromised
Solution Approach 1:
The hollow axle stub design applies local quality by providing structural reinforcement only where needed. The axle stub is hollow to reduce weight, but it includes localized strengthening features such as optimized wall thickness distribution and strategic positioning of mounting points for the stator and rotor units. This allows the axle stub to maintain sufficient strength and rigidity for load-bearing functions while minimizing weight through the hollow construction in non-critical areas.
3Ease of operation
If the rotor unit outer radius is reduced to fit within the wheel fastening region, then the wheel can be mounted without disassembly, but the generator capacity is limited
Solution Approach 1:
The patent employs dynamic positioning of the rotor unit within the hub bore, allowing it to be precisely positioned axially to optimize the balance between outer radius constraints and generator capacity. The rotor unit can be positioned at different axial locations to adjust the effective radius available for the coil arrangement, enabling optimization of power output while maintaining compatibility with wheel fastening region dimensions. This dynamic adjustability allows the system to achieve adequate generator capacity within the spatial constraints imposed by the wheel mounting geometry.
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 operational reliability and simplifies mounting and dismounting by allowing wheel changes without disassembling the axle end arrangement, reduces weight and installation space, and provides high power density for utility vehicles, especially on rough terrain.
Implementation Method 1
the stator unit has a coil arrangement in which, upon rotation of the rotor unit, a voltage is generated
Data Source
AI summary
An axle end arrangement includes a stator unit and a rotor unit, wherein the stator unit is configured to be fixed in a secured manner against rotation about a stub axle relative to an axle stub, wherein the rotor unit is configured to be fixed indirectly or directly on a hub, wherein the stator unit includes a coil arrangement in which, upon rotation of the rotor unit, a voltage is generated, wherein the rotor unit includes a maximum outer radius measured perpendicular to the stub axle, which outer radius is smaller than the smallest distance of a fastening region for a vehicle wheel on the hub from the stub axle.