Integrated Sensor System for Electric Machine Stator Temperature and Rotor Position
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Solution Overview
Problem
Existing electric machines for motor vehicle drive trains face high installation effort due to individually connected sensors and difficulty in temperature capture with tightly wound coil windings, which limits reliable rotational speed and position sensing.
Innovation Solution
Integration of a temperature sensor and rotor condition capture sensor as a common sensor system with an elastic, thermally conductive contact element attached to the stator, reducing assembly effort and ensuring stable temperature capture through a tolerance-compensating design, featuring a snap-in connection for simplified assembly and improved heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are individually connected to the housing via screw connections, then reliable sensor attachment is achieved, but installation effort and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple sensors (temperature sensor, rotor position sensor, rotational speed sensor) into a single integrated sensor unit that attaches to the housing as one component. This merging eliminates the need for individual screw connections for each sensor, reducing assembly complexity while maintaining reliable attachment through a single mounting mechanism.
Solution Approach 2:
The sensor unit serves multiple functions simultaneously - temperature measurement, rotor position detection, and rotational speed sensing - all within a single integrated component. This multi-functionality allows one attachment mechanism to secure multiple sensing functions, thereby reducing the number of connections required while ensuring reliable attachment of all sensors.
2Measurement precision
If temperature sensors are placed in tightly wound coil windings, then temperature capture precision is improved, but access and installation become difficult
Solution Approach 1:
The temperature sensor is nested within the sensor unit housing, which itself attaches to the motor housing. The contact element with thermal conductivity features is integrated into this nested structure, allowing the sensor to be positioned close to the coil windings for precise temperature measurement while remaining accessible through the standardized sensor unit interface for easy installation and manufacturing.
3Adaptability or versatility
If multiple individual sensors are used for temperature and rotor condition capture, then measurement functionality is comprehensive, but the number of components and cable ducts increases
Solution Approach 1:
The patent merges temperature sensing, rotor position sensing, and rotational speed sensing into a single integrated sensor unit. This combination reduces the total number of separate components and their associated cable ducts, while maintaining comprehensive measurement functionality through the coordinated operation of multiple sensors within the unified unit.
Solution Approach 2:
The sensor unit is designed as a universal component that performs multiple measurement functions - temperature capture via the thermally conductive contact element, rotor position detection, and rotational speed sensing. This multi-functionality eliminates the need for separate components for each measurement type, reducing overall component quantity while preserving comprehensive adaptability.
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 solution significantly reduces assembly effort, minimizes screw connections, compensates for installation tolerances, and ensures reliable temperature and rotational speed/position sensing with fewer components and a single cable duct, enhancing the overall efficiency and precision of the electric machine.
Implementation Method 1
a first subsystem having the temperature sensor (4) having an elastic, thermally conductive contact element (9) connected to the temperature sensor (4)
Data Source
AI summary
An electric machine for a drive of a motor vehicle, having a stator, a rotor which can be rotated relative to the stator, a temperature sensor arranged and designed to capture a temperature of the stator and a rotor condition capture sensor which is arranged and designed to capture a rotational speed and/or rotational position of the rotor accommodated in a stator-fixed manner. The temperature sensor and the rotor condition capture sensor are implemented as subsystems of a common sensor system, wherein a first subsystem having the temperature sensor has an elastic thermally conductive contact element connected to the temperature sensor, which contact element is permanently fitted to a contact region of the stator. A hybrid module having this electric machine is also provided.