Vehicle Generator Rotor Assembly With Conical Air-Gap Retention
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Solution Overview
Problem
Existing generator modules face challenges in maintaining an air gap between the rotor and stator assemblies during transport and installation to prevent damage and friction, and in efficiently managing the spring load to minimize operational heat and debris generation.
Innovation Solution
A generator module design featuring a conical surface arrangement with a spring to maintain an air gap and a bearing or threaded plug to manage spring load, along with a sealing system and shipping strap for alignment and protection, allows axial displacement of the rotor assembly and uses a gerotor pump for cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the rotor assembly is kept close to the stator assembly, then the generator module size is reduced, but friction and damage risk increase during transport and installation
Solution Approach 1:
The rotor assembly is made axially displaceable within the housing through a spring-loaded mechanism. During normal operation, the spring maintains minimal spacing for efficiency. During transport or installation, the rotor can be axially displaced to increase spacing and prevent contact with the stator, eliminating friction and damage risk while maintaining compact operational size.
2Object-affected harmful factors
If a spring is used to maintain air gap, then friction and damage are prevented, but operational heat generation increases due to spring load
Solution Approach 1:
The spring mechanism is segmented into modular components including the spring itself, bearing support structures, and adjustable mounting positions. This segmentation allows optimization of the spring load to use the minimum necessary force to maintain the air gap, reducing unnecessary operational heat generation while still preventing friction and damage.
3Reliability
If the rotor assembly is sealed to the housing, then contamination is prevented, but axial displacement capability is restricted
Solution Approach 1:
A seal is introduced as an intermediary element between the rotor assembly and housing. The seal allows the rotor to be sealed to prevent contamination while still permitting controlled axial displacement within the spring-loaded mechanism. The seal accommodates the movement while maintaining the protective barrier against contamination.
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 effectively prevents damage and friction during transport and installation, reduces operational heat, and ensures efficient cooling and alignment, enhancing the durability and reliability of the generator module.
Implementation Method 1
a spring arranged to push the second conical surface into contact with the first conical surface
Implementation Method 2
the first conical surface or the second conical surface includes a plastic surface or a friction paper surface
Data Source
AI summary
A generator module for a vehicle includes a housing with a first conical surface, a rotor assembly with a second conical surface, aligned with the first conical surface, and a spring arranged to push the second conical surface into contact with the first conical surface. In an example embodiment, the first conical surface or the second conical surface includes a plastic surface or a friction paper surface. In an example embodiment, the rotor assembly is axially displaceable within the housing to compress the spring and move the second conical surface away from the first conical surface.