Two-Part End Shield Assembly for Electric Machine Air Gap Control
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Solution Overview
Problem
Existing electric machines face challenges in securing the rotor and stator during transport and assembly, leading to potential damage and complicating the assembly process.
Innovation Solution
The electric machine incorporates a motor housing with a two-part D and N end shield design, featuring an intermediate shield and a cover shield that decouples torque transmission, centering, and axial force absorption, allowing for a low tolerance chain and a secure, easy assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single integrated end shield is used to support the rotor, then the structure is simple, but the tolerance chain from stator to rotor becomes large, resulting in larger air gap and increased electromagnetic losses
Solution Approach 1:
The end shield is divided into two separate components: an intermediate shield that receives the rotor bearing and a cover shield that is releasably fixed to it. This segmentation allows independent positioning and adjustment of each component, enabling precise control of the air gap between stator and rotor, thereby reducing electromagnetic losses while maintaining structural integrity
2Adaptability or versatility
If a single integrated end shield is used, then the structure is compact, but it is difficult to separate the functions of torque transmission, centering, and axial force absorption
Solution Approach 1:
The end shield is divided into two separate components: an intermediate shield that receives the rotor bearing and a cover shield that is releasably fixed to it. This segmentation allows independent positioning and adjustment of each component, enabling precise control of the air gap between stator and rotor, thereby reducing electromagnetic losses while maintaining structural integrity
Solution Approach 2:
The cover shield is designed to be releasably fixed to the intermediate shield, allowing the assembly to be disassembled for transport and reassembled for operation. This dynamic configuration enables the end shield to adapt between different operational states (transport/assembly vs. operation), providing functional versatility while maintaining structural integrity during operation
3Reliability
If the rotor and stator are secured with a screw connection during transport, then damage is prevented, but the assembly process becomes complicated
Solution Approach 1:
The cover shield is designed to be releasably fixed to the intermediate shield, allowing the assembly to be disassembled for transport and reassembled for operation. This dynamic configuration enables the end shield to adapt between different operational states (transport/assembly vs. operation), providing functional versatility while maintaining structural integrity during operation
Data Source
AI summary
An electric machine, in particular for use within the powertrain of a hybrid or fully electric motor vehicle, having a stator and a rotor, said stator and rotor being received in an engine housing The engine housing has at least one A-bearing shield and at least one B-bearing shield for supporting the rotor relative to the engine housing, wherein the A-bearing shield and/or the B-bearing shield has/have a two-part design, in each case having a respective intermediate inner shield which is arranged axially between the stator and a cover shield that can be fixed to the engine housing, and the intermediate shield receives a bearing for the rotor. The cover shield can be releasably fixed to the intermediate shield side facing away from the stator, and the cover shield has centering means for radially centering the intermediate shield.