Resolver Rotor Support Layout for Stable Hybrid Drive Air Gaps
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Solution Overview
Problem
In P0 and P1 hybrid architectures, the radial/angular movement of the emotor rotor due to cantilever mounting causes issues with the resolver, leading to signal processing and speed readout problems due to varying air gaps between the resolver rotor and stator, affecting the emotor's control.
Innovation Solution
A hybrid drive arrangement with a flex plate connected to the rotor and a resolver drive shaft extending coaxially, where the resolver rotor is spaced apart from the flex plate and supported by a resolver rotor support, maintaining a stable air gap with the resolver stator to minimize deflections and ensure accurate signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the resolver rotor is mounted close to the crankshaft/emotor rotor connection, then the structure is compact and simple, but the resolver rotor experiences high radial displacement due to crankshaft flexing and vibration
Solution Approach 1:
A dedicated resolver rotor support structure is introduced as an intermediary component between the crankshaft and the resolver rotor. This support is fixed to the engine block or engine housing rather than being directly attached to the rotating crankshaft, thereby mediating the connection and isolating the resolver rotor from radial displacements caused by crankshaft flexing and vibration.
Solution Approach 2:
The mounting structure is segmented into distinct functional zones: the resolver rotor support is separated from the rotating assembly (crankshaft/emotor rotor) and anchored to the stationary engine structure. This segmentation allows the resolver to be positioned in a stable reference frame independent of the rotating components' dynamic behavior.
2Measurement precision
If the resolver rotor is spaced apart from the flex plate to reduce radial deflection, then the air gap stability improves, but the structure becomes more complex and space-consuming
Solution Approach 1:
The resolver rotor support structure is designed to serve multiple functions: it provides a stable mounting location for the resolver rotor, defines the air gap to the resolver stator, and anchors the resolver assembly to the engine structure. By consolidating these functions into a single integrated component, structural complexity is minimized while achieving the required measurement precision.
3Ease of manufacture
If the resolver rotor is mounted on the rotating assembly, then the structure is simple, but vibration and crankshaft flexing cause varying air gap leading to signal processing issues
Solution Approach 1:
The stationary resolver rotor support acts as a mediator that decouples the resolver from the vibrating rotating assembly. By anchoring the support to the engine block rather than the crankshaft, the resolver operates in a vibration-free environment, ensuring reliable signal generation and detection despite the proximity to rotating components.
Data Source
AI summary
A hybrid drive arrangement for an internal combustion engine is provided, and includes an emotor having a rotor that is connected to the crankshaft and a stator that is fixed relative to the engine. A flex plate is connected for rotation with the rotor, and a resolver drive shaft extends from the flex plate, coaxial with the rotor. A resolver is provided having a resolver rotor that is connected with the resolver drive shaft at a position spaced apart from the flex plate, and a resolver stator is fixed relative to the emotor stator and located in proximity to the resolver rotor. A resolver rotor support acts to support the resolver drive shaft in proximity to the resolver stator. This arrangement isolates deflections caused by the crankshaft so that the radial deflections of the resolver rotor are minimized in order to ensure proper functioning of the resolver.