Electromechanical Converter Housing with Axial Diameter Steps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current electromechanical converter systems for electric vehicles, particularly light electric vehicles, suffer from inefficiency and high maintenance costs due to heat generation, leading to a short service life.
Innovation Solution
The design of an electromechanical converter system with a support housing featuring a first axial section with a larger diameter than the second section, allowing for improved heat dissipation and reduced thermal stress, utilizing a stator and rotor arrangement that optimizes cooling and reduces production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional converter systems are used, then the vehicle can be driven, but high temperatures are generated during operation resulting in high maintenance costs and short service life
Solution Approach 1:
The support housing transitions from a conventional single-section cylindrical design to a two-section design with different diameters. The first section has a larger diameter for heat dissipation while the second section has a smaller diameter for bearing support, effectively adding a dimensional differentiation that separates thermal management functions from mechanical support functions.
Solution Approach 2:
Different sections of the support housing are given different diameters to perform different functions. The first section (larger diameter) is optimized for heat dissipation from the stator, while the second section (smaller diameter) is optimized for bearing support of the rotor shaft. This local differentiation allows each component to operate under optimized conditions.
2Temperature
If the first section of the support housing is enlarged for heat dissipation, then thermal management improves, but the overall device size increases
Solution Approach 1:
The support housing is segmented into two distinct axial sections: a first section with larger diameter for heat dissipation and a second section with smaller diameter for bearing support. This segmentation allows the heat dissipation function to be isolated to only the portion of the housing where it is needed, rather than requiring the entire housing to be enlarged.
Solution Approach 2:
The housing design utilizes axial segmentation with varying radial dimensions. By creating a two-section structure with different diameters along the axial direction, the design achieves enhanced heat dissipation surface area without proportionally increasing the overall volume, as the second section maintains a compact smaller diameter.
3Area of stationary object
If conventional single-section support housings are used, then the structure is simple, but heat dissipation surface area is insufficient
Solution Approach 1:
The housing design adds axial differentiation with two distinct sections having different diameters. This dimensional change along the axial direction creates additional external surface area for heat dissipation without requiring complex internal structures or additional cooling components.
Solution Approach 2:
The first section of the housing is given a larger diameter specifically to provide enhanced heat dissipation surface area for the stator, while the second section maintains a smaller diameter for bearing support. This local quality differentiation increases the total heat dissipation area without making the entire housing complex.
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 configuration enhances the efficiency and longevity of the converter system, reducing maintenance efforts and improving the vehicle's range and performance by effectively managing heat dissipation and using cost-effective materials.
Implementation Method 1
This makes it possible to advantageously dissipate the thermal energy produced primarily in the stator during operation of the energy converter over a large surface of the support housing
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The invention relates to a converter system (1, 1′, 1″) for an electric vehicle and in particular a lightweight electric vehicle. The converter system (1, 1′, 1″) has a supporting housing (10, 10′, 10″) for connecting to the vehicle, has an electromechanical energy converter arranged at least partially in the supporting housing (10, 10′, 10″), said electromechanical energy converter having at least one stator (21, 21′) and a rotor (22, 22′) which is rotatable relative to the stator (21, 21′) about a drive axis (7, 40), and has a power transmitting device which connects the rotor (22, 22′) to a connection element. To permit a particularly cheap design which is easy to maintain and to reduce thermal problems, the supporting housing (10, 10′, 10″) has at least one first (14) and one second axial portion (15). wherein (the first portion (14) has a greater diameter than the second portion (15) in a direction transversely with respect lo the drive axis (7, 40). Here, the second portion (15) of the supporting housing (10, 10′, 10″) is formed for mourning the rotor (22, 22′) and/or the connection element. The rotor (22, 22′) and stator (21, 21′) of the energy converter are arranged at least partially in the first portion (14) of the supporting housing (10, 10′, 10″).