Integrated Rotor Wheel Rim Assembly for Lower Unsprung Mass
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Solution Overview
Problem
The addition of a hub motor to a conventional wheel assembly increases unsprung weight and component count, which is undesirable for electric vehicles.
Innovation Solution
Integrating the rotor of the electric motor assembly into the wheel rim, eliminating the need for fasteners and forming the rim and rotor as a single, unified assembly, and incorporating airflow generation elements to provide cooling to the motor and brake assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a hub motor is added to a conventional wheel assembly, then motive force is provided to rotate the tire, but unsprung weight and component count increase
Solution Approach 1:
The rotor is integrally formed with the wheel rim as a single unified assembly, eliminating the need for separate fastening components. This merging of the motor rotor and wheel rim reduces component count and eliminates fastener weight, thereby providing motive force while minimizing the increase in unsprung weight
2Power
If a hub motor is added to a conventional wheel assembly, then motive force is provided to rotate the tire, but component count increases
Solution Approach 1:
The rotor and wheel rim are integrated into a single assembly, eliminating the need for separate fastening components such as bolts or rivets. This merging reduces the total component count by combining what would traditionally be separate parts into one unified structure
3Ease of manufacture
If the rotor and rim are integrally formed, then assembly is simplified and fastening components are eliminated, but manufacturing complexity increases
Solution Approach 1:
The rotor and wheel rim are designed as a single integrally formed assembly, which eliminates the need for assembly steps involving fasteners and simplifies the final assembly process. The integral design consolidates multiple components into one, reducing assembly complexity despite potentially more complex manufacturing of the unified structure
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
Reduces unsprung mass and simplifies assembly while enhancing efficiency and cooling the motor and brake components.
Implementation Method 1
application of a rotating electric field in the stator that causes corresponding rotation of the rotor
Data Source
AI summary
A wheel assembly for a vehicle may include a rim on which a tire is mountable, and an electric motor assembly operably coupled to the rim. The electric motor assembly may include a rotor, a stator and power electronics. The electric motor assembly may be operably coupled to a battery of the vehicle to provide motive force to the rim to rotate the tire with the rim responsive to application of a rotating electric field in the stator that causes corresponding rotation of the rotor under control of the power electronics. The rim and the rotor are integrally formed as a combined assembly without any fastening means therebetween.