Integrated Electro-Hydraulic Machine with Magnetic Coupling
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Solution Overview
Problem
Existing power transmission systems that integrate electromechanical and hydraulic systems face challenges such as high production costs, complex designs, and inefficiencies in power transmission, particularly when using internal or external gear machines.
Innovation Solution
An integrated electromechanical and hydraulic system is developed, featuring an electric machine with a stator and rotor separated by a radial diamagnetic gap, coupled with a hydraulic machine through mechanical and hydro-mechanical couplings, allowing for bidirectional power transmission and robust cooling mechanisms, enabling efficient power conversion between electric and hydraulic systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If internal gear machines are used for integration, then power transmission between electromechanical and hydraulic systems is achieved, but production cost increases and design complexity increases
Solution Approach 1:
The patent merges the electric motor and hydraulic pump into a single integrated unit where the motor rotor is directly coupled to the pump rotor through a shared magnetic coupling mechanism. This eliminates the need for separate internal gear machines and their complex mechanical connections, thereby reducing design complexity while maintaining power transmission capability.
Solution Approach 2:
The integrated system uses a universal magnetic coupling mechanism that serves dual functions: transmitting mechanical power from the motor to the pump, and enabling bidirectional operation where the pump can drive the motor in regenerative braking mode. This multi-functionality reduces the need for separate specialized components, simplifying the overall design.
2Power
If internal gear machines are used for integration, then power transmission between electromechanical and hydraulic systems is achieved, but production cost increases
Solution Approach 1:
By combining the motor and pump into a single integrated assembly with shared housing and magnetic coupling components, the patent reduces the total number of parts that need to be manufactured and assembled. This consolidation lowers production costs through economies of scale and reduced manufacturing complexity.
Solution Approach 2:
The patent uses magnetic field coupling as a non-contact power transmission mechanism, effectively 'copying' the magnetic field across the air gap between motor rotor and pump rotor. This eliminates the need for complex mechanical gear transmissions and their associated high-cost manufacturing requirements.
3Ease of operation
If external gear machines are used for integration, then electromechanical driving is achieved, but power transmission efficiency is insufficient and cost increases
Solution Approach 1:
The patent replaces traditional mechanical gear transmission with magnetic field coupling for power transmission. This substitution eliminates mechanical friction, gear tooth sliding, and mechanical losses associated with external gear machines, thereby significantly improving power transmission efficiency while maintaining ease of electromechanical driving.
Solution Approach 2:
The magnetic field acts as an intermediary between the motor rotor and pump rotor, transferring power without direct mechanical contact. This magnetic intermediary eliminates the energy losses inherent in mechanical gear interfaces, improving overall system efficiency.
4Volume of moving object
If compact integration is implemented, then power-to-volume ratio is improved, but cooling efficiency may be compromised
Solution Approach 1:
The patent nests the pump rotor inside the motor rotor assembly, with the pump housing contained within the motor housing. This nested configuration achieves compact integration and high power-to-volume ratio while providing internal pathways for coolant flow that maintain effective cooling despite the compact size.
Solution Approach 2:
The patent utilizes the radial dimension by creating a magnetic coupling across a radial air gap between the motor rotor and pump rotor. This radial arrangement allows compact integration in the axial direction while maintaining adequate space for cooling pathways and magnetic flux distribution, thereby preserving cooling efficiency.
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
The solution results in a more compact, robust, and efficient power transmission system with improved cooling efficiency, reducing production costs and enhancing power-to-volume ratios, making it suitable for tight spaces and varying operational conditions.
Implementation Method 1
a rotor separated from the stator and the one or more windings by a radial diamagnetic gap
Data Source
AI summary
An integrated electromechanical and hydraulic system is disclosed which includes an electric machine, the electric machine includes a casing, a stator adapted to remain stationary within the casing, one or more electrically insulated windings coupled to the stator, a rotor separated from the stator and the one or more windings by a radial diamagnetic gap, electrical power couplings, and a first mechanical power couplings, and a hydraulic machine also disposed in the housing, the hydraulic machine having hydro-mechanical couplings as well as a second mechanical power couplings, wherein the second mechanical power couplings are coupled to the first mechanical power couplings.