Nested Clutch in Integrated Starter Generator for Axial Space Reduction
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Solution Overview
Problem
Conventional hybrid power systems with integrated starter generators (ISGs) face challenges of large axial space occupation, high mass, and manufacturing costs due to the series arrangement of components, which complicates the structure and increases complexity.
Innovation Solution
The proposed hybrid power system incorporates a hollow ring-shaped ISG with a clutch at its center, integrating the rotor and clutch flywheel, and features a stator mounted on the driving motor casing, utilizing circumferentially distributed magnetic poles and tooth-slot iron cores for efficient coil and conductor mounting, along with a cooling system that optimizes the stator's structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the ISG, clutch and driving motor are arranged in series in the direction of the transmission shaft, then the structure is simple, but the axial space occupied is large
Solution Approach 1:
The clutch is nested inside the hollow ring-shaped ISG, with the clutch flywheel integrated with the ISG rotor. The clutch housing is positioned within the ISG stator, creating a compact nested arrangement that significantly reduces axial space while maintaining structural simplicity
Solution Approach 2:
The clutch flywheel and ISG rotor are merged into a single integrated component, and the clutch housing is combined with the ISG stator structure. This merging of components eliminates the need for separate mounting spaces and reduces overall axial length
2Device complexity
If the ISG, clutch and driving motor are arranged in series, then the structure is simple, but the mass is relatively big
Solution Approach 1:
The clutch flywheel and ISG rotor are merged into a single integrated component, eliminating redundant materials and reducing overall mass. The clutch housing is combined with the ISG stator structure, further reducing the total mass of the hybrid power system
Solution Approach 2:
By nesting the clutch inside the ISG, the patent eliminates the need for separate mounting structures and support components, thereby reducing the total mass of the system while maintaining structural integrity
3Device complexity
If the ISG, clutch and driving motor are arranged in series, then the structure is simple, but the manufacturing cost is relatively high
Solution Approach 1:
The integrated design of the clutch flywheel with the ISG rotor and the clutch housing with the ISG stator reduces the total number of parts that need to be manufactured and assembled, thereby lowering manufacturing costs despite the innovative structural arrangement
4Temperature
If the stator is mounted on the driving motor casing with cooling system integration, then cooling efficiency is enhanced, but the structural complexity increases
Solution Approach 1:
The driving motor casing serves multiple functions: it provides structural support for the stator mounting and simultaneously acts as a cooling system component. This multi-functionality enhances cooling efficiency without significantly increasing structural complexity, as the casing already exists and is repurposed for thermal management
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 axial length, saves space and weight, lowers manufacturing costs, and enhances cooling efficiency, while maintaining functions like engine starting, electricity generation, and power assistance.
Implementation Method 1
the iron core of the stator is provided with a coil winding on the side that faces the rotor
Implementation Method 2
the iron core of the rotor is provided with a plurality of permanent magnets on the side that faces the stator
Implementation Method 3
the iron core of the rotor is provided with a squirrel-cage conductor on the side that faces the stator
Implementation Method 4
a cooling system that optimizes the stator's structure
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
Disclosed is an integrated starter generator (ISG), comprising a stator (4) and a rotor (3). The stator and the rotor are oppositely arranged and are both provided with an annular iron core, a coil winding (121, 131) is arranged on the side, facing the rotor, of the iron core (120, 130) of the stator, a squirrel-cage conductor (123) or a plurality of permanent magnets (133) are arranged on the side, facing the stator, of the iron core (122, 132) of the rotor, and the rotor and the stator are spaced by a certain distance to form an air gap plane. In a hybrid power system installed with the integrated starter generator, a clutch (111) is arranged in an inner ring of the integrated starter generator in a nested manner. By arranging the clutch in the ISG, the axial length of the clutch is completely or partially covered by the axial length of the ISG, and thus the system space is reduced.