Hybrid Pump Rotor Shaft Mounting for Noise Reduction
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Solution Overview
Problem
Hybrid pump assemblies in motor vehicles experience undesirably high noise levels during operation due to the interaction between mechanical and electric drives.
Innovation Solution
A pump assembly design featuring a mechanical drive, an electric drive, and a planetary gearbox, where the electric drive's rotor shaft is mounted via a ball bearing on the pump housing and within the planetary gearbox, minimizing mechanical loads on the ball bearing and optimizing the air gap between the rotor and stator for reduced noise and power losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the rotor shaft is mounted on the housing via a ball bearing and in the planetary gearbox, then the noise level is reduced, but the axial forces on the ball bearing increase
Solution Approach 1:
The planetary gearbox acts as an intermediary element between the rotor shaft and the housing. By mounting the rotor shaft in the planetary gearbox rather than directly on the housing, the system reduces noise transmission while the gearbox structure helps manage the axial forces through its gear stage configuration
Solution Approach 2:
The design optimizes the air gap between rotor and stator by adjusting the mounting position of the rotor shaft, which changes the magnetic field parameters and reduces power losses. This parameter optimization also influences the force distribution on the ball bearing
2Loss of energy
If the air gap between rotor and stator is optimized, then power losses are reduced, but the structural complexity increases
Solution Approach 1:
The rotor shaft is merged with the sun gear of the planetary gearbox, creating a combined component that eliminates the need for separate mounting structures. This integration simplifies the overall structure while allowing precise control of the air gap between rotor and stator for optimal power transmission
Solution Approach 2:
The planetary gearbox serves multiple functions: it acts as a speed reducer, provides structural support for the rotor shaft, and enables precise air gap control. This multi-functionality reduces the need for additional components, thereby simplifying the structure while achieving optimal power transmission
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 design reduces operating noise and minimizes power losses and axial forces on the ball bearing, resulting in a quieter and more efficient pump assembly with a simplified, cost-effective structure.
Implementation Method 1
the rotor shaft is mounted at one side on a housing of the pump assembly via a ball bearing
Implementation Method 2
the mechanical drive and the electric drive are coupled to one another via the planetary gearbox
Data Source
AI summary
A pump assembly for a motor vehicle, comprising at least one mechanical drive, at least one electric drive, and at least one planetary gearbox, wherein the mechanical drive and the electric drive are coupled to one another via the planetary gearbox, the electric drive comprising a rotor shaft that is designed as a hollow shaft, wherein the rotor shaft is mounted at one side on a housing of the pump assembly via a ball bearing and at the other side in a gear stage of the planetary gearbox.