Modular Electric Motor for Camshaft Phasers
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Solution Overview
Problem
Existing electric motors for camshaft phasers lack a modular construction that is easy to assemble, leading to complex and costly connections and limited flexibility in configuration.
Innovation Solution
A modular electric motor design comprising a main motor module with a pot-shaped metal housing and a plug-in module made of plastic, where the main motor module contains the core functions, including a rolling bearing, and is supplied with current through standardized insulation displacement connections, allowing for various plug-in modules with different functionalities such as sensor systems and control electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a non-modular design with integrated bearings and connections is used, then structural integrity is maintained, but assembly complexity increases and manufacturing cost rises
Solution Approach 1:
The electric motor is divided into separate modular components: a motor module containing the stator and rotor, and a housing module containing the bearings and housing. These modules are designed to be assembled together through simple connection elements, eliminating the need for complex integrated structures and reducing assembly difficulty.
Solution Approach 2:
Connection elements serve as intermediaries between the motor module and housing module. These standardized connectors simplify the joining process, replacing complex direct integrations and enabling easy assembly and disassembly while maintaining structural integrity.
2Ease of operation
If standardized modular connections are used, then assembly is simplified and flexibility increased, but connection strength may be reduced
Solution Approach 1:
Multiple functions are merged into the connection elements: mechanical joining, electrical connection, and sealing. This integration ensures that a single standardized connector provides sufficient overall strength while simplifying the assembly process, as no separate fastening mechanisms are needed.
Solution Approach 2:
The connection elements utilize composite construction combining different materials (metal contacts, plastic housing, sealing materials) to achieve both the required mechanical strength and the simplified standardized interface for easy assembly.
3Device complexity
If a single rolling bearing supports all forces, then device complexity is reduced, but bearing load increases
Solution Approach 1:
The single rolling bearing in the motor module is designed as a universal support element that handles multiple force components (radial and axial loads) through its geometry and arrangement. This multi-functional bearing reduces the number of components needed while distributing the total load effectively.
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
The modular design simplifies assembly, reduces costly connections, and allows for standardized power supply and flexible combinations of modules, enhancing mechanical stability and heat dissipation while maintaining a compact external contour.
Implementation Method 1
The single rolling bearing of the electric motor is configured in such a way that it can absorb axial forces, radial forces and tilting moments
Implementation Method 2
electrical connections between the plug-in module and the main motor module are established by connections, in particular insulation displacement connections, which can be produced by fitting together the modules
Data Source
AI summary
An electric motor suitable for an electric camshaft phaser comprises a main motor module and a plug-in module electrically and mechanically connected thereto. The main motor module comprises a housing shell, a stator and a rotor mounted in the housing shell by way of a rolling bearing. The main motor module is inserted into the plug-in module, and electrical connections between the plug module and the main motor module are established by insulation displacement connections, which can be produced by joining the modules in the axial direction.