Motor Shaft Locking Mechanism With Spring-Loaded Form-Fit Engagement
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Solution Overview
Problem
Existing locking devices for electric motor drive units in vehicles require high actuating forces and occupy significant installation space, complicating assembly and potentially leading to inefficiencies.
Innovation Solution
A locking mechanism with a form-fit element actuated by an elastic force transmission element, allowing for low-force actuation and compact design, integrated with a position sensor assembly and multifunctional shaft adapter for efficient locking and external excitation of the rotor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional locking mechanisms are used, then reliable shaft locking is achieved, but high actuating forces are required and installation space is significant
Solution Approach 1:
The locking mechanism uses a dynamic spring-loaded form-fit element that can be actuated in an axial stroke movement. The elastic force transmission element (spring) provides dynamic pretensioning and bracing forces, allowing the form-fit element to engage with the shaft-side complement when alignment is achieved, while reducing the required actuating force compared to conventional static locking mechanisms
Solution Approach 2:
The locking mechanism is segmented into distinct functional components: the form-fit element, the elastic force transmission element, and the movement mechanism. This segmentation allows each component to be optimized independently, with the form-fit element providing reliable engagement while the spring provides the necessary forces, thereby reducing the overall actuating force requirement
2Reliability
If conventional locking mechanisms are used, then shaft locking is achieved, but device complexity and installation space are increased
Solution Approach 1:
The locking mechanism merges the form-fit element, elastic force transmission element, and actuation mechanism into a single integrated assembly that can be received by a compact housing. This merging reduces the number of separate components and simplifies assembly, thereby reducing device complexity while maintaining reliable shaft locking functionality
Solution Approach 2:
The form-fit element serves multiple functions: it provides the locking engagement with the shaft-side complement, stores elastic energy through the spring, and can be actuated axially to engage or disengage the lock. This multi-functionality reduces the need for additional components, simplifying the overall device complexity
3Reliability
If conventional locking mechanisms are used, then shaft locking is achieved, but significant installation space is occupied
Solution Approach 1:
The locking mechanism is designed with a nested structure where the form-fit element, spring, and actuation components are arranged concentrically around the shaft. The form-fit element can be received within a housing that is integrated with the motor housing, and the spring is nested within the form-fit element assembly, thereby minimizing the radial and axial space required for the locking mechanism
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 reduces component count and installation space, simplifies assembly, and enables energy-efficient locking and rotor excitation, while ensuring reliable shaft locking even in emergency scenarios.
Implementation Method 1
at least one elastic force transmission element, in particular in the form of at least one spring, for pretensioning/bracing of the actuatable form-fit element along the shaft
Implementation Method 2
in the form of at least one separate spring or a separate spring element and/or in the form of at least one spring element portion integrated into the actuatable form-fit element
Data Source
AI summary
A locking device for an electric motor drive unit having a locking mechanism for locking a lockable shaft of the electric motor drive unit and an electric drive for actuating the locking mechanism received by a housing of the locking device together with the locking mechanism. The housing receives a position sensor assembly that comprises a signal transmitter and a sensor component, which interacts with the signal transmitter and detects the position of a rotor of an electric motor to commutate the electric motor.