Modular Motor Assembly for Alternative Fuel Vehicles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The high manufacturing costs and space requirements of alternative fuel vehicles are exacerbated by the complexity and size of pre-assembled electric motor assemblies, which are typically purchased as complete units, limiting efficiency and increasing weight.
Innovation Solution
A modular automotive drive assembly is proposed, comprising separate electric motor components, including a stator and rotor, and a transmission assembly with gears, allowing for independent outsourcing and vertical stacking, thereby reducing costs and space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pre-assembled electric motor assembly is purchased from a supplier, then the vehicle can be manufactured with a complete motor system, but the manufacturing cost significantly increases
Solution Approach 1:
The motor assembly is divided into separate components (stator, rotor, housing) that can be manufactured independently by different suppliers and then assembled. This segmentation allows each component to be optimized and sourced separately, reducing the overall manufacturing cost while maintaining system reliability.
2Reliability
If a pre-assembled electric motor assembly is used, then the motor system is complete and functional, but the space required in the vehicle increases
Solution Approach 1:
The rotor is positioned inside the stator, creating a nested configuration where the rotating component is housed within the stationary component. This nesting arrangement minimizes the overall volume of the motor assembly while preserving complete motor functionality.
3Reliability
If a pre-assembled electric motor assembly is purchased, then the vehicle has a functional motor system, but the overall vehicle weight increases
Solution Approach 1:
By segmenting the motor into separate components that can be manufactured independently, each part can be optimized for minimal weight while maintaining operational requirements. This allows for more efficient material usage and weight reduction compared to a monolithic pre-assembled unit.
4Ease of manufacture
If separate motor components are used, then the manufacturing cost and space requirements are reduced, but the device complexity increases
Solution Approach 1:
The separate motor components (stator, rotor, housing) are designed to merge into a single integrated assembly through straightforward coupling mechanisms. This merging approach maintains the manufacturing and space benefits of separate components while minimizing the complexity of final assembly.
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 modular design reduces manufacturing costs and minimizes space requirements, enhancing efficiency and performance by allowing for more compact and cost-effective installation of electric motor systems in alternative fuel vehicles.
Implementation Method 1
at least one magnet and at least one conductive coil configured such that when current flows through the at least one conductive coil, the second electric motor component rotates relative to the first electric motor component
Data Source
AI summary
An automotive drive assembly includes a housing configured to be installed in an automobile, a first electric motor component coupled to the housing, a second electric motor component rotatably coupled to the first electric motor component, the first and second electric motor components jointly including at least one magnet and at least one conductive coil configured such that when current flows through the at least one conductive coil, the second electric motor component rotates relative to the first electric motor component, and a transmission assembly including at least one gear coupled to the second electric motor component such that the rotation of the second electric motor component causes movement of the at least one gear. The second electric motor component and the transmission assembly are coupled to the housing such that the transmission assembly substantially supports the second electric motor component when the housing is installed in the automobile.