Electric Prime Mover Shaft Cable Sealing in Compact Vehicles
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Solution Overview
Problem
Existing electrical machines in motor vehicles face challenges in securely routing and sealing high-current cables, particularly in compact designs, where increased shaft diameter for accommodation leads to weight and bulkiness, while smaller diameters compromise strength, and conventional sealing methods fail to prevent water and dust ingress, causing potential short circuits and fire hazards.
Innovation Solution
A caulking member is used to securely route and seal cables within the shaft, providing a tight seal against water and moisture, maintaining structural strength without increasing shaft diameter, and an elastic guard member supports the cables to prevent wear and tension issues, ensuring reliable operation in varying orientations and motions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the shaft diameter is increased to accommodate high-current cables, then the cables can be securely routed, but the electric machine becomes bulkier and heavier
Solution Approach 1:
The cable routing channel is nested within the existing shaft structure, utilizing the internal space of the shaft rather than increasing its external dimensions. The seal member is integrated into the cable routing channel, creating a nested configuration that secures cables without adding to the shaft's external diameter, thereby avoiding increased weight and bulkiness.
2Reliability
If the shaft diameter is increased to accommodate high-current cables, then the cables can be securely routed, but the electric machine becomes bulkier
Solution Approach 1:
The cable routing channel is nested within the existing shaft structure, utilizing the internal space of the shaft rather than increasing its external dimensions. The seal member is integrated into the cable routing channel, creating a nested configuration that secures cables without adding to the shaft's external diameter, thereby avoiding increased weight and bulkiness.
3Device complexity
If conventional sealing methods are used, then the structure remains simple, but water and dust ingress causes short circuits and fire hazards
Solution Approach 1:
A seal member is introduced as an intermediary element between the cable routing channel and the external environment. This seal member protrudes into the cable routing channel and works in conjunction with a groove in the shaft to create an effective sealing barrier that prevents water and dust ingress while maintaining a relatively simple overall structure.
4Volume of moving object
If the shaft diameter is reduced to maintain compact size, then the electric machine remains compact, but the shaft strength is compromised
Solution Approach 1:
The cable routing channel and seal member are designed and positioned in advance during the shaft manufacturing process. The groove is formed in the shaft at a predetermined location, and the seal member is configured to fit precisely into this groove. This preliminary arrangement ensures that the shaft maintains its structural integrity while providing adequate space for cable routing and sealing without requiring increased diameter.
Data Source
AI summary
A vehicle includes: an electric prime mover; a frame member acting as a load bearing member of the vehicle; and a structural member functionally connected to the frame member. The structural member is capable of supporting the electric prime mover rotatably. The electric prime mover includes a shaft fixedly mounted to the structural member and that is disposed substantially in a lateral direction of the vehicle. The shaft fixedly supports a stationary member of the electric prime mover and the shaft rotatably supports a rotating member of the electric prime mover. A cable assembly extends outward from the stationary member through a cable path defined by the shaft. The cable path includes a portion provided with a caulking member capable of securely holding the cable assembly thereat. The cable assembly includes an external sheath forming at least an outer periphery of the cable assembly.