Outrunner Motor-Generator Packaging in Vehicle Drivetrains
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Solution Overview
Problem
Inrunner style electric motors integrated into vehicle drivetrains face challenges such as difficult packaging due to stator coil layout and require permanent mechanical attachments, making servicing and balancing complex, leading to increased production costs and design modifications.
Innovation Solution
An outrunner style electric motor-generator with a rotor surrounding a stator, allowing for efficient packaging and modular design with a drop-in module featuring a disconnect clutch or mass damper, enabling adaptable integration into existing transmission infrastructures and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an inrunner style electric motor is integrated into a torque converter, then the electric motor can be incorporated into the drivetrain to increase fuel economy and provide launch assist, but packaging the stator in the engine becomes difficult due to the layout of the coils in the stator
Solution Approach 1:
The patent inverts the traditional inrunner motor configuration by using an outrunner motor configuration where the rotor is on the inside and the stator is on the outside. This reversal allows the stator coils to be arranged in a more space-efficient manner that fits within the torque converter housing, resolving the packaging difficulty while maintaining integration capability.
Solution Approach 2:
The outrunner motor configuration allows the rotor to be nested within the stator assembly, with the rotor positioned inside the torque converter and the stator surrounding it. This nested arrangement optimizes space utilization within the torque converter housing while accommodating both components.
2Strength
If inrunner electric motors are attached to transmission torque converters via welded joints or rivets, then the motor can be securely attached, but servicing and balancing of both the motor and torque converter become difficult to carry out
Solution Approach 1:
The motor assembly is designed as a separable unit that can be detached from the torque converter without permanent attachment. This segmentation allows the motor to be removed for servicing, balancing, or replacement while leaving the torque converter intact, eliminating the need for complex disassembly associated with welded or riveted joints.
Solution Approach 2:
The attachment mechanism transitions from static permanent joints to a dynamic, removable connection system. This allows the motor to be securely attached during operation while enabling easy removal when servicing is needed, providing both strength during use and ease of repair when required.
3Reliability
If the torque converter is made unique to the WIT for permanent attachment, then the motor can be securely integrated, but the engine and transmission must be redesigned to accommodate the integration, increasing vehicle production costs
Solution Approach 1:
The motor assembly is designed with universal mounting interfaces that can attach to standard torque converters without requiring custom-designed components. This multi-functionality allows the same motor design to be integrated into various engine and transmission configurations, eliminating the need for redesigns and reducing production costs while maintaining reliable integration.
4Volume of moving object
If an outrunner style electric motor-generator is used with compact design, then efficient packaging is achieved and manufacturing costs are reduced, but the stator must be positioned around the rotor which requires different design considerations
Solution Approach 1:
The patent applies the outrunner configuration where the stator is positioned on the outside surrounding the rotor, inverting the traditional inrunner design. This inversion achieves more compact packaging while the design complexity is managed through standardized motor components and interfaces that simplify the overall integration process.
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 outrunner configuration achieves efficiency gains and cost reductions by allowing the motor-generator to be compactly integrated into existing systems, facilitating easier servicing and broader vehicle compatibility, thus lowering production costs and enhancing efficiency.
Implementation Method 1
a rotor with a plurality of magnets at least partially surrounding a stator including a plurality of coils
Data Source
AI summary
Methods and systems for an electric motor-generator in a vehicle are provided. In one example, an electric motor-generator is provided that includes an engine interface configured to rotationally couple to a first engine, a transmission interface configured to rotationally couple to a first transmission of the first engine, and a rotor with a plurality of magnets at least partially surrounding a stator including a plurality of coils. The rotor is rotationally coupled to the engine interface and the transmission interface.