Polygonal Stator Housing for Torque Transmission
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Solution Overview
Problem
All-wheel-drive motor vehicles face energy inefficiency and increased noise and vibration due to conventional torque transmission devices, which also face space constraints in modern applications.
Innovation Solution
A torque transmitting device with a motor featuring a rotor and stator housing design that includes multiple sidewall sections and connecting portions, along with magnets, to reduce noise and vibration, and a powertrain that includes this device for efficient switching between all-wheel-drive and two-wheel-drive modes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional cylindrical stator housing is used in the motor, then the motor structure is simple and easy to manufacture, but the motor exhibits larger magnitudes of vibration and higher levels of noise
Solution Approach 1:
The stator housing is divided into multiple sidewall sections (e.g., four sidewall sections) connected by connecting portions, transforming the single cylindrical structure into a segmented polygonal structure. This segmentation reduces vibration and noise while maintaining manufacturability through modular assembly
Solution Approach 2:
The connecting portions between sidewall sections are designed with curved surfaces having specific radii of curvature. These curved transitions reduce stress concentrations and vibration compared to sharp corners, while the overall polygonal shape replaces the cylindrical form
2Power
If the motor size is increased to meet rising output requirements, then the motor can deliver more power, but the space allocated for the motor is constrained in modern applications
Solution Approach 1:
The motor adopts a polygonal stator housing design that optimizes the arrangement of magnets and windings in the available space. By changing from a cylindrical to a polygonal cross-section, the design better utilizes the radial and axial dimensions, achieving higher power density without increasing overall motor volume
Solution Approach 2:
The design changes geometric parameters including the number of sidewall sections, connecting portion radii, and magnet arrangements to optimize power density. These parameter optimizations allow the motor to deliver higher output power within constrained volume by improving space utilization efficiency
3Reliability
If an all-wheel-drive powertrain is used, then traction between wheels and road is improved, but energy consumption increases due to transmission of engine output to both front and rear axles
Solution Approach 1:
The torque transmission device uses a motor-driven clutch assembly that can dynamically engage or disengage the connection between the engine output and the axles. This allows the system to switch between all-wheel-drive mode (for improved traction) and two-wheel-drive mode (for energy efficiency), adapting to varying driving conditions
Solution Approach 2:
The motor-driven clutch assembly automatically engages or disengages based on driving conditions, enabling the powertrain to self-regulate between all-wheel-drive and two-wheel-drive modes. This eliminates the need for constant manual intervention and optimizes energy consumption while maintaining necessary traction
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 results in a motor with reduced noise and vibration levels, improved power density, and enhanced energy efficiency, allowing for efficient operation in constrained spaces while effectively switching between drive modes.
Implementation Method 1
The electric motor includes a rotor, which includes a shaft and a field coil wound around a portion of the shaft, and a stator surrounding at least a portion of the rotor
Implementation Method 2
A first magnet disposed within the housing... attached to at least a portion of an internal surface of a first connecting portion
Data Source
AI summary
A motor (21) includes a stator (30) and a rotor (40). The stator includes a housing (31) accommodating magnet(s) (32) and including multiple sidewalls (33) and connecting portions (34) adjoining neighboring sidewalls. A sidewall includes zero or more flat segment (35, 38) and zero or more curved segments (38, 36) having one or more radii. A connecting portion includes a substantially flat segment or a curved segment having one or more radii and adjoins two neighboring sidewalls. A torque transmitting device (15) includes the motor and a clutch (22) actuated by the motor to transmit or cease transmitting engine (11) output to driven mechanism(s) (17, 18, 12, 13, 14). A powertrain includes the torque transmitting device to switch between drive modes with the torque transmitting device to engage or disengage engine output with axles.