Vehicle Electric Drive Spacer Layout for Variable Stator Lengths
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Solution Overview
Problem
Existing electric drives for vehicles require dedicated housing designs for each stator length, limiting flexibility and increasing manufacturing costs.
Innovation Solution
A spacer is attached to the stator at a radial position outside the winding head, allowing a single housing design to accommodate stators of varying lengths, and a cooling system with adjustable oil jet rings for effective heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dedicated housing design is used for each stator length, then the stator fits exactly into the stator accommodation space, but the manufacturing cost increases and flexibility decreases
Solution Approach 1:
A spacer element is introduced as an intermediary component between the stator and the housing stop. This spacer absorbs the dimensional variations of different stators, allowing a single housing design to accommodate multiple stator lengths while maintaining precise positioning. The spacer acts as a mediator that decouples the fixed housing geometry from the variable stator dimensions.
Solution Approach 2:
The positioning function is segmented between the fixed housing stop and the adjustable spacer. Instead of requiring the entire housing to be redesigned for each stator length, the positioning task is divided into a fixed reference point (stop) and an adjustable element (spacer) that can be selected or modified to match different stator dimensions.
2Adaptability or versatility
If a single housing design is used for different stator lengths, then manufacturing costs decrease and flexibility increases, but the stator may not fit precisely without additional components
Solution Approach 1:
The spacer serves as a simple intermediary component that bridges the gap between the fixed housing and variable stator. Rather than complicating the housing structure itself, the solution introduces a separate, simple element that handles the adaptability requirement, keeping the housing design clean and straightforward.
Solution Approach 2:
The housing is designed with universal characteristics through the use of a standard stop feature that works with multiple stator lengths when combined with appropriate spacers. This universal stop design eliminates the need for multiple specialized housing variants, reducing overall system complexity while maintaining adaptability.
3Device complexity
If the stator is positioned directly against the stop, then the structure is simple, but stators of different lengths cannot be accommodated with the same housing
Solution Approach 1:
The positioning system is segmented into two independent parts: a fixed stop provided by the housing and a variable spacer that interfaces with the stator. This segmentation allows the housing to remain simple while the spacer handles the variability required for different stator lengths.
Solution Approach 2:
The positioning arrangement becomes dynamic rather than fixed. Instead of a rigid direct connection between housing and stator, the system allows for adjustment through the selection or modification of spacer elements, enabling the same housing to adapt to different stator lengths.
Data Source
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AI summary
Electric drive (1) for a vehicle (100), the electric drive (1) comprising: - a stator (3) comprising a stator winding (5) and a stator core (6) having a longitudinal axis (7) and opposing axial first and second face sides (8, 9), the stator winding (5) forming a first winding head (10) at the first face side (8) and a second winding head (11) at the second face side (9); - a housing (12) with an interior (13) that forms a stator accommodation space (14) and a radial stop (15), which delimits the stator accommodation space (14) axially; and - a spacer (26) being attached to the first face side (8) at a radial position more outward than the first winding head (10) and abutting against the stop (15).