Monolithic Stator Ring-Internal Gear Assembly for Compact Hub Drives
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Solution Overview
Problem
The existing stator ring-internal gear assemblies for wheel hub drives, particularly in electric bicycles, are bulky and heavy due to their axial size and require multiple components, leading to increased production costs.
Innovation Solution
A stator ring-internal gear assembly is designed with a positive connection between the stator ring and internal gear, forming a monolithic unit through over-moulding, eliminating the need for fasteners and reducing the number of components, resulting in a compact and lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the stator ring and internal gear are connected using traditional fastening methods (screws, fasteners), then the connection is strong and reliable, but the assembly becomes heavier and more complex with additional components
Solution Approach 1:
The patent combines the stator ring and internal gear into a single integrated component where the internal gear is directly formed as part of the stator ring structure. This eliminates the need for separate fasteners and reduces the total number of components while maintaining structural integrity through the monolithic design.
Solution Approach 2:
The stator ring serves multiple functions simultaneously: it provides the structural support of the stator, forms the gear teeth for torque transmission, and eliminates the need for separate fastening components. This multi-functionality reduces overall assembly complexity while maintaining connection strength.
2Reliability
If the stator ring and internal gear are connected using traditional fastening methods, then the assembly is durable, but the axial size increases making the overall assembly bulkier
Solution Approach 1:
By merging the stator ring and internal gear into a single integrated component, the patent eliminates the axial space required for separate fastening elements and their associated clearance requirements. The gear teeth are formed directly from the stator ring material, reducing the overall axial dimension while maintaining structural durability.
3Ease of manufacture
If multiple separate components are used for the stator ring and internal gear assembly, then the assembly is easier to manufacture individually, but the production cost increases and the assembly process becomes more complex
Solution Approach 1:
The patent combines multiple components into a single monolithic structure that can be manufactured as one piece using additive manufacturing or other single-step fabrication processes. This eliminates the need for separate manufacturing of individual components and subsequent assembly operations, reducing production costs and simplifying the manufacturing process.
Solution Approach 2:
The patent employs additive manufacturing or advanced forming techniques that enable the creation of complex monolithic structures with optimized geometry. This manufacturing approach allows for the production of integrated stator ring-gear assemblies with reduced material waste and lower production costs compared to traditional multi-component manufacturing and assembly processes.
Data Source
AI summary
A stator ring-internal gear assembly for a transmission device comprising a planetary gear of a wheel hub drive for a vehicle, the assembly may include a stator ring of an electrically operable electric motor device of the wheel hub drive for providing a motor torque and an internal gear of the transmission device for translating the provided motor torque into a net torque. The stator ring and the internal gear may be directly fixed to one another by positive connection in a non-rotatable and tension-resistant manner. The stator ring and the internal gear may form a mono-lithic unit.