Integrated Motor Position Sensor Layout for Compact Powertrains
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Solution Overview
Problem
The existing design of vehicle powertrain assemblies is not optimized for spatial layout and cost efficiency due to the axial space occupied by motor position sensors and the need for long wiring harnesses to connect sensors and electronic control assemblies.
Innovation Solution
The powertrain assembly integrates a motor position sensor with a sensor rotor at the output end of the motor's rotary shaft and a sensor stator within the electronic control assembly, eliminating the need for additional axial space and reducing the overall size and weight of the assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the motor position sensor is arranged at opposite sides of the motor in the axial direction and connected through a wiring harness, then the sensor can monitor the motor position, but the axial size of the powertrain assembly expands
Solution Approach 1:
The patent merges the motor position sensor with the electronic control assembly by integrating the sensor rotor into the motor rotor and the sensor stator into the electronic control assembly housing. This combination eliminates the need for separate sensor mounting space and long wiring harnesses, thereby reducing the axial size of the powertrain assembly while maintaining position monitoring functionality.
Solution Approach 2:
The patent repositions the sensor rotor from a separate axial location to being integrated within the motor rotor structure. By utilizing the radial dimension of the motor rotor rather than occupying additional axial space, the sensor system achieves position monitoring without increasing the axial footprint of the powertrain assembly.
2Length of moving object
If the motor position sensor is integrated into the powertrain assembly, then the axial size is reduced, but the wiring harness length increases
Solution Approach 1:
The patent combines the sensor stator directly with the electronic control assembly housing, eliminating the need for external wiring harnesses to connect the sensor to the control unit. The sensor signals are now internally connected within the integrated assembly, reducing wiring complexity and potential failure points.
3Adaptability or versatility
If separate motor position sensor and electronic control assembly are used, then the sensor can be independently positioned, but the overall assembly size and weight increase
Solution Approach 1:
The patent integrates the sensor components with the motor and electronic control assembly structures, eliminating redundant housings and mounting hardware. This merging reduces the overall material usage and assembly weight while the sensor functionality remains embedded within the motor rotor and control assembly, providing sufficient positioning capability for the application.
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 configuration reduces the axial size of the powertrain assembly, saves space on the vehicle chassis, and lowers production costs by minimizing the need for lengthy wiring harnesses and additional electromagnetic shielding.
Implementation Method 1
a motor position sensor, configured to monitor a position of the motor, includes a sensor rotor and a sensor stator
Data Source
AI summary
A powertrain assembly designed for vehicles, comprising a motor with a first rotary shaft, a motor position sensor including a sensor rotor and a sensor stator, and an electronic control assembly, where the sensor rotor is arranged at one end of the first rotary shaft within the electronic control assembly, and the sensor stator is arranged in the electronic control assembly.