Drive Train Actuator Layout With Nested Rotor and Circuit Carrier
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Solution Overview
Problem
Existing drive systems for motor vehicle actuation means in the drive train require significant installation space, numerous components, and high production costs, particularly due to the axial structural height and radial extension of conventional actuator designs.
Innovation Solution
A structural concept featuring an electric motor with a motor housing shell, a circuit carrier with a control unit, and a gearbox with a gearbox housing shell, where the circuit carrier is arranged between the electric motor and the gearbox output shaft, and the rotor shaft is accommodated within the gearbox output shaft, reducing axial extension and radial space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the circuit carrier is arranged axially on the end face of the motor (conventional arrangement), then the control unit can be properly positioned, but the radial installation space increases significantly (mushroom head effect)
Solution Approach 1:
The circuit carrier is moved from an axial arrangement on the motor end face to a radial arrangement within the motor housing, changing the spatial dimension of component placement. This eliminates the mushroom head effect and reduces radial installation space while maintaining proper control unit positioning.
Solution Approach 2:
The circuit carrier is nested within the motor housing structure, utilizing the existing radial space inside the motor. This integration allows the control unit to be positioned within the motor's internal volume rather than extending outward, reducing overall radial footprint.
2Reliability
If a cover and additional environmental seal are added to protect the printed circuit board, then environmental protection is improved, but the axial structural height and number of components increase
Solution Approach 1:
The circuit carrier housing is merged with the motor housing structure, eliminating the need for a separate cover component. The motor housing itself provides the environmental protection function, reducing axial structural height and component count while maintaining reliability.
Solution Approach 2:
The motor housing serves multiple functions: it contains the motor components, provides structural support, and simultaneously protects the circuit carrier from environmental factors. This multi-functionality eliminates the need for additional protective covers.
3Measurement precision
If two separate sensors (rotor position sensor and output shaft angle sensor) are mounted on opposite sides, then both sensing functions are achieved, but the integration complexity and installation space increase
Solution Approach 1:
Both the rotor position sensor and output shaft angle sensor are integrated onto a single circuit carrier, merging the sensing functions into one location. This reduces integration complexity and allows both sensors to be positioned on the same side rather than opposite sides.
Solution Approach 2:
The circuit carrier serves as an intermediary platform that hosts both sensors, allowing them to be co-located and integrated within the same structural plane. This mediator enables simplified wiring and signal routing compared to opposite-side mounting.
Data Source
AI summary
A structural concept of a drive for an actuation device in a drive train of a motor vehicle, contains an electric motor with a motor housing shell, a circuit carrier with a control unit for controlling the electric motor, and an output shaft of a gearbox with a gearbox housing shell. The rotor shaft of the electric motor is arranged axially with respect to the output shaft of the gearbox, and the rotor shaft of the electric motor is accommodated in the output shaft in a rotatably mounted manner in the region of the gearbox housing shell. The circuit carrier is arranged between the electric motor and the output shaft of the gearbox, and the rotor shaft leads through a cutout in the circuit carrier.