Hub Bearing Resolver Integration for Compact In-Wheel Drives

Solution Overview

Problem

Existing in-wheel drive devices face challenges due to the large size and heavy weight of sensors, such as resolvers, which are necessary for detecting motor position but complicate the configuration of the device.

Innovation Solution

The proposed wheel structure incorporates a resolver that is positioned adjacent to the hub bearing, allowing the resolver rotor to be fixedly coupled to the hub body, thereby reducing the size and weight of the resolver and optimizing the configuration of the in-wheel drive device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a resolver is provided to detect the position of the motor in an in-wheel drive device, then the motor position can be detected for control purposes, but the sensor becomes large in size and heavy in weight, making it difficult to configure the in-wheel drive device

Engineering Contradiction:

Improvemotor position detectionVSAvoidresolver weight

Core Design Contradiction:

Measurement precisionVSWeight of moving object

Solution Approach 1:

The resolver is merged with the hub bearing structure. The resolver rotor is integrated into the hub body, and the resolver stator is integrated into the hub outer race, combining two previously separate components into one unified structure. This reduces the overall weight and simplifies the configuration of the in-wheel drive device while maintaining position detection functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hub bearing structure is given multiple functions: it serves both as a bearing component and as a housing for the resolver. The hub body accommodates the resolver rotor, and the hub outer race accommodates the resolver stator, allowing the same structural elements to perform both mechanical support and sensor housing functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If a resolver is provided to detect the position of the motor in an in-wheel drive device, then the motor position can be detected for control purposes, but the sensor becomes large in size and heavy in weight, making it difficult to configure the in-wheel drive device

Engineering Contradiction:

Improvemotor position detectionVSAvoidin-wheel drive device configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The resolver is merged with the hub bearing structure. The resolver rotor is integrated into the hub body, and the resolver stator is integrated into the hub outer race, combining two previously separate components into one unified structure. This reduces the overall weight and simplifies the configuration of the in-wheel drive device while maintaining position detection functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hub bearing structure is given multiple functions: it serves both as a bearing component and as a housing for the resolver. The hub body accommodates the resolver rotor, and the hub outer race accommodates the resolver stator, allowing the same structural elements to perform both mechanical support and sensor housing functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Volume of moving object

If the resolver is positioned adjacent to the hub bearing with the resolver rotor fixedly coupled to the hub body, then the overall size of the wheel structure is reduced, but the integration requirements become more stringent

Engineering Contradiction:

Improvewheel structure sizeVSAvoidresolver integration precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The resolver is merged with the hub bearing structure. The resolver rotor is integrated into the hub body, and the resolver stator is integrated into the hub outer race, combining two previously separate components into one unified structure. This reduces the overall weight and simplifies the configuration of the in-wheel drive device while maintaining position detection functionality.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12202349B2Wheel structure including hub bearing and vehicle including the same

Publication Date: 2025.01.21 HYUNDAI MOBIS CO LTD

AI summary

A wheel structure includes: a wheel; a rotary part disposed inside the wheel and configured to rotate together with the wheel; a fixing part facing the rotary part; a hub bearing disposed at one side of the rotary part and the fixing part; and a resolver facing the hub bearing and configured to detect a position of the hub bearing. The hub bearing includes: a hub body fixedly coupled to the rotary part; and a hub outer race fixedly coupled to the fixing part. The resolver includes: a resolver rotor; and a resolver stator. The resolver rotor is fixedly coupled to the hub body.