Clamp Mechanism for Electric Machine Stator Mounting
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Solution Overview
Problem
Existing hybrid/electric vehicle powertrains face challenges in securely mounting electric machine stators within housings, leading to potential axial and radial movement, noise, vibration, and harshness (NVH) issues.
Innovation Solution
A clamp mechanism engages stepped surfaces on both the electric machine stator and the housing, applying an axial load to secure the stator, preventing movement and addressing NVH issues by forcing the stator's surfaces into engagement with corresponding stepped surfaces within the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stator is mounted within the housing using conventional methods, then the assembly is simple, but axial and radial movement occurs causing noise, vibration, and harshness issues
Solution Approach 1:
The mounting structure is segmented into multiple functional elements: a clamp assembly with adjustable clamping surfaces, stepped engagement surfaces on the housing, and positioning features on the stator. This segmentation allows each element to perform a specific function (radial clamping, axial positioning, movement prevention) while collectively achieving stable stator mounting without excessive overall complexity
Solution Approach 2:
The clamp assembly is nested within the housing structure, with the clamp positioned inside the housing cavity to engage both the stator and housing surfaces. This nesting approach allows the mounting mechanism to be integrated within the existing housing boundaries rather than adding external mounting structures, achieving reliable fixation while maintaining compact overall design
2Reliability
If a clamp mechanism is used to secure the stator, then axial and radial movement is prevented, but the device complexity increases
Solution Approach 1:
The clamp assembly combines multiple functions into a single integrated component: radial clamping action, axial positioning, and movement constraint are all achieved through the coordinated interaction of the clamp body, clamping surfaces, and engagement features. This merging of functions reduces the number of separate parts needed compared to using multiple independent fasteners and positioning elements
Solution Approach 2:
The clamp assembly acts as an intermediary element between the housing and the stator, providing a controlled interface that transfers and distributes mounting forces. The clamp's stepped surfaces and engagement features mediate the interaction between the rigid housing and the stator, enabling precise positioning and secure fixation while protecting both components from excessive stress concentrations
Data Source
AI summary
A vehicle includes a housing, an electric machine configured to propel the vehicle, and a clamp. The housing defines an internal cavity, and has first and second stepped surfaces extending radially inward and into the cavity. The electric machine is disposed within the cavity. The electric machine has a stator that includes third and fourth stepped surfaces that extend radially outward. The clamp engages the first and third stepped surfaces, and axially forces the fourth stepped surface into engagement with the second stepped surface.