Reconfigurable EV Motor Stator to Eliminate Gearbox Weight
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Solution Overview
Problem
Electric motors and propulsion elements in electric vehicles, such as gearboxes, contribute significantly to the weight and size of the vehicle, occupying valuable space and reducing efficiency, which is undesirable for urban mobility vehicles.
Innovation Solution
Adaptable electric motors with a stator unit comprising a plurality of winding elements connected by dynamic mechanical linkage systems, including ball joints and scissor mechanisms, allowing for adjustable size and shape, and a rotor unit with shuttles that can operate without a gearbox.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If traditional electric motors with gearboxes are used in electric vehicles, then propulsion power can be achieved, but vehicle weight increases significantly and cabin space is reduced
Solution Approach 1:
The patent applies the dynamics principle by making the stator unit adaptable and reconfigurable through dynamic mechanical linkage systems. The stator can change its circumferential length and shape during operation, allowing the motor to optimize its characteristics for different propulsion requirements without needing a heavy gearbox for torque multiplication. This dynamic adaptability enables the motor to deliver high propulsion power when needed while maintaining a lighter overall vehicle weight.
Solution Approach 2:
The patent employs parameter changes by allowing the stator unit to modify its physical parameters (circumferential length, shape) during operation. The dynamic mechanical linkage system enables the stator to transition between different configurations, changing its effective parameters to match varying propulsion demands. This eliminates the need for fixed-gearbox solutions and reduces overall vehicle weight while maintaining propulsion capability.
2Power
If large electric motors and gearboxes are installed in electric vehicles, then propulsion requirements are met, but valuable cabin space is occupied and real estate is consumed
Solution Approach 1:
The adaptable stator unit with dynamic mechanical linkages allows the motor to change its shape and size during operation. This dynamic capability enables the motor to achieve high propulsion power in a more compact form factor compared to traditional fixed-design motors with gearboxes, thereby reducing the space occupied in the vehicle and preserving more cabin area.
3Volume of moving object
If gearboxes are employed in electric vehicles to reduce motor size, then space is saved, but the gearbox itself adds significant weight and generates performance losses
Solution Approach 1:
The patent extracts and eliminates the gearbox from the propulsion system by using an adaptable stator unit that can change its characteristics during operation. The dynamic mechanical linkage system allows the stator to provide torque multiplication and speed variation functions internally, removing the need for a separate gearbox component. This extraction eliminates the energy losses associated with gearbox operation while maintaining the ability to optimize motor size.
4Ease of manufacture
If fixed-size electric motors are used, then manufacturing is simpler, but adaptability to different operating conditions is reduced
Solution Approach 1:
The patent implements dynamics by creating a stator unit that can dynamically reconfigure its shape and size during operation through mechanical linkage systems. While the base structure can be manufactured using standard processes, the inclusion of dynamic linkages and adjustable components enables the motor to adapt to different operating conditions, speeds, and torque requirements, significantly enhancing operational versatility.
Solution Approach 2:
The adaptable stator unit serves multiple functions through its ability to change configuration. It can operate as a motor with different effective sizes and characteristics depending on operational needs, providing both high-speed low-torque and low-speed high-torque capabilities within a single device. This multi-functionality replaces what would traditionally require multiple fixed motors or a motor-gearbox combination.
Data Source
AI summary
An electric motor can comprise a stator unit comprising a plurality of winding elements, wherein each pair of consecutive winding elements of the plurality of winding elements can be coupled by a dynamic mechanical linkage system comprising a first set of ball joints, a second set of ball joints and a scissor mechanism coupling the first set of ball joints and the second set of ball joints. The electric motor can further comprise a rotor unit comprising at least one shuttle that can be magnetically coupled to the plurality of winding elements and mechanically coupled to a rail structure of the stator unit, wherein the at least one shuttle can follow a circumferential length of the stator unit, such that a circumferential length of the electric motor can be altered according to a circumferential length of the stator unit.