Integrated Rotating Electric Machine Gearbox Design
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Solution Overview
Problem
Rotating electrical machines used in electric vehicles face limitations in achieving a large speed range without the need for external gearboxes, which are typically required to optimize performance and efficiency.
Innovation Solution
Integration of a gearbox unit and clutch unit within the rotating electrical machine, allowing for at least two different gear states with frictional coupling elements, enabling direct and decoupled rotary connections between the runner shaft and tray package, and utilizing a planetary gear for torque and speed translation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If an external gearbox is used to achieve a large speed range, then the speed range and top speed are improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent integrates the gearbox unit directly into the rotating electrical machine by combining the runner shaft with the gearbox input shaft, merging two previously separate components into one integrated assembly. This eliminates the need for external gearboxes while achieving the desired speed range, thereby reducing device complexity and space requirements.
Solution Approach 2:
The runner shaft is designed to serve multiple functions: it acts as both the rotor of the rotating electrical machine and the input shaft of the gearbox. This multi-functionality allows the system to achieve a large speed range without adding external components, resolving the contradiction between speed range improvement and device complexity reduction.
2Adaptability or versatility
If a gearbox unit is integrated into the rotating electrical machine, then the need for external gearboxes is reduced, but the device complexity increases
Solution Approach 1:
The gearbox is segmented into two distinct units: a planetary gear unit for torque and speed transformation, and a clutch unit for decoupling the runner shaft from the tray package. This segmentation allows each unit to perform its specific function efficiently while maintaining overall system flexibility, and the modular design facilitates easier manufacturing and assembly.
Solution Approach 2:
The clutch unit provides dynamic coupling and decoupling capabilities, allowing the runner shaft to be selectively connected or disconnected from the tray package. This dynamic control enables the system to adapt to different operating conditions, achieving versatility while managing complexity through intelligent control rather than mechanical complexity.
3Ease of operation
If frictional clutch elements are used for coupling, then seamless gear changes are achieved, but energy loss increases
Solution Approach 1:
The frictional clutch elements enable continuous torque transmission during gear changes, ensuring seamless transitions between different gear states. The clutch maintains engagement throughout the switching process, preventing interruptions in the useful action of torque transmission and enabling smooth, continuous operation without energy loss from disengagement and re-engagement cycles.
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 allows for efficient speed and torque translation, reducing the need for external gearboxes, enhancing flexibility, and enabling high acceleration and top speeds with seamless gear changes, while maintaining reliability and simplicity in design.
Implementation Method 1
a planetary gear for torque and speed translation
Implementation Method 2
the clutch unit provides a friction -friendly coupling element, for example on one of theThe front side of the runner's tile package couples this friction -controlled
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a rotating electric machine (10) comprising a stator (12) having a winding head (16) at each axial end and comprising a rotor (40), which is rotatably mounted in an opening in the stator (12) and which has a rotor shaft (24) and a laminated rotor core (26). According to the invention, the electric machine comprises a bearing unit (30) for the rotatable mounting of the rotor shaft (24) with respect to the laminated rotor core (26), a transmission unit (46), a coupling unit (42, 48), which is designed to provide at least two coupling states for coupling the rotation of the rotor shaft (26) to the laminated rotor core (26) and, in at least one of the coupling states, to couple the rotor shaft (24) to the laminated rotor core (26) by means of the transmission unit (46).