Hybrid Motor Rotor Segmentation and Spring Pressing
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Solution Overview
Problem
Existing electric motors for hybrid modules face challenges in efficiently transmitting torque and maintaining structural integrity while accommodating a resolver rotor and stator within a compact, durable, and efficiently cooled design.
Innovation Solution
The design incorporates a rotor with a tubular rotor carrier, multiple segments, end plates, and a spring element that presses against a radial wall, along with a resolver rotor and stator within a hybrid module housing, featuring a shaft for torque transmission and seals for cooling fluid containment, ensuring secure engagement and efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a compact rotor design with multiple segments is used, then the device complexity is reduced and manufacturing is simplified, but the structural integrity and torque transmission capability may be compromised
Solution Approach 1:
The rotor is divided into multiple rotor segments (108) that circumscribe the cylindrical surface, each segment being independently manufacturable and then assembled together. This segmentation allows for simpler manufacturing of individual components while maintaining the overall structural integrity through precise assembly and connection mechanisms between segments.
Solution Approach 2:
The rotor segments are disposed within and circumscribe the cylindrical surface of the rotor carrier, creating a nested configuration where the segments fit within the carrier structure. This nesting arrangement allows the segmented rotor to achieve compact dimensions while maintaining structural coherence through the carrier's radial wall that provides support.
2Strength
If a spring element is added to press rotor segments against the radial wall, then the structural integrity and torque transmission are improved, but the device complexity increases
Solution Approach 1:
A spring element (102) is introduced that can dynamically adjust the pressing force applied to the rotor segments against the radial wall. This dynamic mechanism ensures consistent torque transmission capability while accommodating variations in assembly tolerances and operational conditions, maintaining structural integrity without requiring overly rigid or complex fixed positioning systems.
Solution Approach 2:
The spring element automatically maintains contact pressure between the rotor segments and the radial wall through its elastic properties, providing self-adjusting force without requiring external control systems. This self-service mechanism ensures reliable torque transmission while minimizing the need for additional control components or complex adjustment mechanisms.
3Temperature
If cooling seals are implemented in the hybrid module, then the temperature management is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The seals (234, 236) are positioned to serve multiple functions: they provide cooling fluid containment while also sealing interfaces between different housing portions and the rotor assembly. This multi-functional approach allows a single sealing component to address both cooling efficiency and general sealing requirements, reducing the need for separate sealing systems and simplifying manufacturing.
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 configuration enhances torque transmission efficiency, maintains structural integrity, and effectively manages cooling within the hybrid module, addressing the need for a robust and efficient electric motor for hybrid applications.
Implementation Method 1
The spring element presses the first end plate, the plurality of rotor segments, and the second end plate against the radial wall
Data Source
AI summary
A rotor for an electric motor includes an axis, a rotor carrier a plurality of rotor segments, a first end plate, a second end plate, and a spring element. The rotor carrier has a tubular portion with a cylindrical surface and a radial wall extending radially outwardly from the cylindrical surface. The plurality of rotor segments circumscribe the cylindrical surface. The first end plate is disposed at a first axial end of the plurality of rotor segments adjacent to the radial wall. The second end plate is disposed at a second axial end of the plurality of rotor segments. The spring element presses the first end plate, the plurality of rotor segments, and the second end plate against the radial wall. The spring element includes a ring portion and a plurality of segments extending axially from the ring portion.