360° Motor Enclosure Mount for Low-Vibration Drive Test Stands
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Solution Overview
Problem
Existing drive modules for electric motor vehicle drive train test stands face challenges in achieving high rigidity and effective vibration damping, especially at high speeds, and require complex realignment of electric motors, which complicates the testing process.
Innovation Solution
A drive module design featuring a base frame that encloses the electric motor 360° circumferentially, with a conical motor mount providing a robust connection and high structural resonant frequency, allowing for precise alignment and reduced vibration, and incorporating a vibration-damping base frame made of mineral concrete or polymer concrete.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the electric motor is rigidly mounted to the base frame using conventional methods, then mechanical vibrations are reduced, but the electric motor requires complex realignment and cannot be easily replaced
Solution Approach 1:
The base frame is segmented into a modular motor mount structure with separate alignment features. The motor mount includes distinct components: a mounting plate with bolt holes, alignment pins, and a vibration-damping element. This segmentation allows the electric motor to be independently positioned and aligned using standardized features, eliminating complex realignment procedures while maintaining rigid mechanical connection for vibration reduction.
Solution Approach 2:
A vibration-damping element is introduced as an intermediary component between the electric motor mounting surface and the base frame. This intermediary element serves dual functions: it provides a compliant interface that absorbs mechanical vibrations while maintaining precise alignment through integrated alignment features. The vibration-damping element eliminates the need for complex realignment during motor replacement while still achieving effective vibration reduction.
2Stability of the object's composition
If the base frame provides high rigidity for high-speed operation, then machine dynamics are improved, but vibration damping capacity is reduced
Solution Approach 1:
The base frame is constructed using composite materials, specifically a hybrid structure combining a rigid metal framework with vibration-damping polymer concrete or mineral concrete. The metal framework (steel or aluminum alloy) provides the necessary structural rigidity and high natural frequency for high-speed operation, while the polymer concrete or mineral concrete portions provide superior vibration damping capacity. This composite construction resolves the contradiction by simultaneously achieving high machine dynamics and effective vibration damping.
Solution Approach 2:
Different regions of the base frame are assigned different material properties to optimize local functions. The motor mount structure and load-bearing framework use high-rigidity materials (metal) to ensure machine dynamics and structural stability. The vibration-damping elements and non-critical support structures use vibration-absorbing materials (polymer concrete or mineral concrete) to reduce harmful vibrations. This local differentiation of material quality allows the base frame to simultaneously achieve high rigidity where needed and vibration damping where beneficial.
3Object-generated harmful factors
If the electric motor is enclosed 360° by the base frame, then vibration damping is enhanced, but motor replacement becomes more complex
Solution Approach 1:
The 360° enclosing structure is segmented into modular sections with standardized interfaces. The motor mount includes discrete components (mounting plate, alignment pins, vibration-damping element) that can be independently assembled and disassembled. This segmentation allows the electric motor to be easily removed and replaced by simply detaching the modular components, while the complete 360° enclosure maintains optimal vibration damping in all directions.
4Ease of manufacture
If conventional mounting methods are used, then manufacturing is simpler, but rigidity and vibration damping are insufficient at high speeds
Solution Approach 1:
The base frame uses composite materials (metal framework combined with polymer concrete or mineral concrete) that can be manufactured using conventional casting and assembly processes. The metal framework provides the rigid structural skeleton, while the concrete portions are cast in place to provide both structural support and vibration damping. This composite approach maintains manufacturing simplicity while achieving the high rigidity and vibration damping capacity required for high-speed electric motor operation.
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 solution enhances machine dynamics by minimizing mechanical vibrations and enabling easy replacement of the electric motor without complex realignment, ensuring accurate testing of high-speed electric motor vehicle drive trains.
Implementation Method 1
incorporating a vibration-damping base frame made of mineral concrete or polymer concrete
Data Source
AI summary
A drive module (10) for a drive train test stand includes an electric motor (12) and a base frame (11), wherein the base frame (11) carries the electric motor (12). The drive module (10) according to the invention is characterized in that the drive module (10) encloses a housing (13) of the electric motor (12) circumferentially along a circumferential direction of the housing (12) to 360°. The invention further relates to a corresponding drive train test stand and to a method for producing the drive module.