Integrated Shaft Generator Layout for Protected Power Generation
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Solution Overview
Problem
Existing shafts with integrated generators for torque transmission in drive trains, such as cardan shafts, face increased space requirements and exposure to external influences like dust and centrifugal forces, which affect their performance and durability.
Innovation Solution
The generator is integrated within the shaft body, arranged in a rotationally fixed manner, with a primary part movable relative to a secondary part along the shaft's longitudinal direction, reducing space requirements and providing a protective housing while generating electricity through relative movement between the parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the generator is arranged outside the shaft body, then the generator can be easily assembled and maintained, but the space requirements increase and the generator is exposed to external influences such as dust and centrifugal forces
Solution Approach 1:
The generator is integrated within the hollow interior of the shaft body, with the coil arranged in the hollow space and the magnet arrangement positioned within the coil. This nested configuration allows the generator components to be protected by the shaft body while maintaining a compact structure that does not increase external dimensions.
2Volume of moving object
If the generator is integrated within the shaft body, then space requirements are reduced and protection from external influences is improved, but the assembly complexity increases
Solution Approach 1:
The shaft body serves multiple functions: it transmits torque as a drive shaft and simultaneously houses the generator components (coil and magnet arrangement) within its hollow interior. This multi-functionality eliminates the need for separate housing structures, reducing overall space requirements while avoiding excessive assembly complexity.
3Power
If the magnet arrangement is rotatably mounted relative to the coil, then relative movement is achieved for electricity generation, but the device complexity and space requirements increase
Solution Approach 1:
The magnet arrangement is configured to rotate together with the shaft, creating dynamic relative movement between the magnets and the stationary coil. This dynamic configuration allows electricity generation through electromagnetic induction while maintaining a simple, integrated structure without requiring separate rotational mounting mechanisms.
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 minimizes space usage, reduces exposure to external loads, and enhances the shaft's durability by integrating the generator within the shaft body, allowing efficient energy generation and stress monitoring through sensors.
Implementation Method 1
A current is induced in the generator in a known manner by a relative movement between the primary and secondary parts
Data Source
Figure 1~2
AI summary
The present invention relates to a rotatably mounted shaft with a shaft body (2) and a generator (6) comprising a secondary part (10) and a primary part (8) arranged within the secondary part (10) and movable relative to the secondary part (10). To avoid increased space requirements, reduce loads acting on the shaft, and protect the generator (6), the generator (6) is provided in a rotationally fixed manner within the shaft body (2). The primary part (8) is movable along a longitudinal direction (L) of the secondary part (10), wherein the longitudinal direction (L) of the secondary part (10) is radially spaced from a longitudinal axis of the shaft body (2). In a procedural aspect, the present invention provides a method for operating a rotatably mounted shaft with a generator (6) integrated into the shaft.