Electric Machine B-Side Shield Integration
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Solution Overview
Problem
Existing electrical machines and gear actuators in motor vehicles face challenges in reducing size and manufacturing costs, while also simplifying production, particularly in the integration of electrical coils and bearing shields.
Innovation Solution
The design incorporates a B-side bearing shield that combines the functions of holding and providing electrical connections to the stator, using a metal ring embedded in a plastic carrier, which reduces the number of components and simplifies assembly by eliminating the need for an interconnection ring, and features a press-fit electrical connection system for stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional separate components (bearing shields, interconnection rings, electrical connections) are used, then mechanical integrity and electrical connectivity are achieved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines the bearing shield and interconnection ring into a single integrated bearing shield assembly. The bearing shield includes an integrated interconnection ring that provides both mechanical support for the rotor bearing and electrical connection pathways, eliminating the need for separate interconnection ring components and reducing assembly steps while maintaining structural integrity
Solution Approach 2:
The bearing shield is designed to perform multiple functions simultaneously: it serves as a mechanical barrier protecting the stator winding, provides structural support for the rotor bearing, and incorporates electrical connection pathways for contacting the interconnection ring. This multi-functional design reduces the total number of components needed in the electrical machine
2Ease of manufacture
If more components are used for electrical connections and mechanical support, then reliability and functionality are improved, but manufacturing costs and production complexity increase
Solution Approach 1:
The electrical connection pathways are integrated directly into the bearing shield structure rather than being separate components. The bearing shield includes conductive elements that form the electrical connection pathways, eliminating the need for separate electrical connection components and reducing the total part count while maintaining electrical connectivity functionality
3Volume of moving object
If axial height and radial size are reduced, then device compactness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The bearing shield and interconnection ring are manufactured as a single integrated component, which eliminates the need for precise assembly and alignment between separate parts. This integration reduces the cumulative tolerance requirements and simplifies manufacturing while achieving compact dimensions
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 reduces the axial height and radial size of the electrical machine, lowers manufacturing costs, and simplifies production by integrating multiple functions into fewer components, while maintaining mechanical integrity and stability.
Implementation Method 1
The electrical machine comprises a stator with an electrical coil... the magnetic fields created using the magnet of the rotor have a suitable magnetic fields of the stator
Data Source
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AI summary
The invention relates to an electric machine (14), in particular an electric motor of a motor vehicle, with a stator (24) comprising an electric coil (28) which is covered at its end face by a B-side end shield (54). The B-side end shield (54) has an electrical connection (78) to which one end (80) of the electric coil (28) is fixed and electrically connected. The invention further relates to a transmission actuator (16) of a motor vehicle.