In-wheel Motor Weight Reduction via Segmented Suspension Housing
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Solution Overview
Problem
In-wheel motor systems lack effective buffering and absorption of road surface impacts, and face challenges in weight reduction, ease of assembly, and low defect rates, particularly with the integration of Hall sensors.
Innovation Solution
The in-wheel motor driving apparatus separates the suspension housing and shaft, using different materials for each component, and incorporates a molding-connected Hall sensor substrate for improved assembly and maintenance, allowing for reduced weight and lower defect rates by using carbon steel for the shaft and aluminum for the suspension housing, and allowing the Hall sensor substrate to be easily replaced without disassembling the motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a suspension housing and suspension assembly are added to buffer road surface impacts, then the ability to buffer and absorb impact is improved, but the weight of the in-wheel motor increases
Solution Approach 1:
The suspension housing is separated from the shaft into independent components. The suspension housing contains the suspension assembly (buffer spring and damper), while the shaft remains a separate rotational component. This segmentation allows the suspension housing to be made of lightweight aluminum alloy while maintaining impact buffering capability, and enables independent optimization of each component's material and structure.
Solution Approach 2:
Different materials are used for different components: the suspension housing is made of aluminum alloy (lightweight material) while the shaft is made of carbon steel (high strength material). This composite material approach allows the suspension housing to provide impact buffering with reduced weight, while the shaft maintains its rotational strength without carrying the suspension components' weight.
2Device complexity
If the Hall sensor is integrated into the motor assembly, then the structural compactness is improved, but the ease of assembly and maintenance deteriorates
Solution Approach 1:
The Hall sensor is mounted on the suspension housing as a separate component rather than being integrated into the motor assembly. The suspension housing acts as an independent platform that carries both the suspension assembly and the Hall sensor, allowing the Hall sensor to be assembled separately and then the entire suspension housing assembly to be installed as one unit.
Solution Approach 2:
The suspension housing serves as an intermediary platform that carries the Hall sensor and positions it relative to the motor assembly. This intermediary structure allows the Hall sensor to be mounted independently on the suspension housing while maintaining its functional relationship with the motor, facilitating easier assembly and replacement without disassembling the motor itself.
3Device complexity
If the Hall sensor is integrated into the motor assembly, then the structural compactness is improved, but the ease of repair and replacement deteriorates
Solution Approach 1:
The Hall sensor is separated from the motor assembly and mounted on the suspension housing. This segmentation allows the Hall sensor to be replaced by removing only the suspension housing assembly, without needing to disassemble the motor components. The suspension housing acts as a removable carrier that can be detached and reattached, enabling quick Hall sensor replacement.
Solution Approach 2:
The suspension housing serves as a disposable or replaceable carrier for the Hall sensor. When the Hall sensor needs replacement, the entire suspension housing assembly can be removed and replaced with a new one, or the Hall sensor can be accessed and replaced on the existing suspension housing without affecting the motor assembly. This approach enables quick replacement similar to discarding and recovering a module.
4Weight of moving object
If different materials are used for the suspension housing and shaft, then the weight is reduced and material appropriateness is improved, but the manufacturing complexity increases
Solution Approach 1:
The suspension housing and shaft are manufactured as separate components using different materials (aluminum alloy for suspension housing, carbon steel for shaft). This segmentation allows each component to be manufactured independently with its optimal material, avoiding the need for complex multi-material manufacturing processes or material joining operations. Each component can be produced using standard manufacturing methods for its respective material.
Solution Approach 2:
The in-wheel motor uses a composite material structure where the suspension housing is made of aluminum alloy and the shaft is made of carbon steel. This composite material approach allows each component to be optimized for its specific function: aluminum alloy provides lightweight suspension housing, while carbon steel provides strong shaft. The separation of components simplifies the manufacturing process compared to attempting to create a monolithic multi-material 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
This solution effectively buffers road surface impacts, reduces the weight of the in-wheel motor, simplifies Hall sensor assembly and maintenance, and lowers defect rates by using distinct materials for the suspension housing and shaft, and enables easy replacement of the Hall sensor substrate without disassembling the motor.
Implementation Method 1
a suspension assembly coupled into the suspension housing and provided with at least one buffer spring
Data Source
AI summary
The present invention relates to an in-wheel motor driving apparatus for reducing weight, improving Hall sensor assembly performance, and reducing a defect rate. According to one embodiment of the present invention, the weight of an in-wheel motor can be reduced by separating a suspension housing and a shaft and applying different materials thereto. Furthermore, the ease of assembling a Hall sensor can be improved, and the defect rate can be reduced.