Roll Stabiliser Actuator with Integrated Vernier Motor Transmission
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing active roll stabilizers face challenges in optimizing installation space and drive efficiency, particularly due to the axial arrangement of electric motors and transmissions, which limits their compactness and increases weight and energy consumption.
Innovation Solution
The integration of a Vernier motor with the transmission within the electric motor housing allows for a compact design, reducing the axial extent of the actuator and enabling a more efficient and lightweight roll stabilizer, where the transmission is arranged within the rotor and stator, and a planetary gear is used to achieve high torque and quiet operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the electric motor and transmission are arranged axially next to each other in the actuator housing, then the drive can achieve high torque through gear translation, but the axial extent of the actuator increases significantly
Solution Approach 1:
The transmission is arranged essentially within the electric motor, with the planetary gear set nested inside the motor housing. The sun gear is concentric with the motor shaft, planet gears are arranged radially around the sun gear, and the ring gear forms the outer boundary. This nested configuration allows the transmission to be contained within the motor's radial dimensions rather than extending axially, significantly reducing the overall axial extent of the actuator while maintaining the high torque capability through gear multiplication.
2Length of moving object
If the transmission is arranged within the electric motor, then the axial extent is reduced, but the installation space and drive efficiency need optimization
Solution Approach 1:
The electric motor and transmission are merged into a single integrated actuator unit. The motor housing serves as the transmission housing, the motor shaft is directly connected to the sun gear, and the ring gear is mounted on the housing. This merging eliminates the need for separate motor and transmission housings, reduces the number of coupling interfaces, and allows the transmission to be positioned optimally within the motor's radial space, thereby maintaining high drive efficiency while achieving compact axial dimensions.
3Volume of moving object
If a planetary gear is used inside the electric motor, then high torque is achieved with compact dimensions, but the manufacturing complexity increases
Solution Approach 1:
The actuator housing serves multiple functions: it houses the electric motor, contains the planetary gear transmission, provides mounting surfaces for the stabilizer elements, and acts as the structural connection to the vehicle chassis. The motor shaft serves both as the rotor shaft and as the sun gear. The ring gear is mounted directly on the housing, eliminating the need for a separate transmission case. This multi-functionality reduces the number of separate components and assembly steps, thereby reducing manufacturing complexity despite the sophisticated planetary gear design.
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
This configuration results in a significantly reduced installation space requirement, improved energy efficiency, lower noise, and reduced weight, enhancing the comfort and stability of vehicle handling by minimizing rolling movements without the need for additional space, and is applicable to various actuator systems.
Implementation Method 1
an electric motor used for driving has an output shaft which is offset from the axis of rotation of the stabilizer elements
Implementation Method 2
A passive roll stabilizer is separated and an actuator consisting of engine and transmission is connected between the stabilizer elements. This actuator can twist the two stabilizer elements against each other
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a roll stabiliser for a motor vehicle, comprising an actuator (135, 235) having a housing (137, 237) with a first stabiliser element (110, 210) coupled thereto and an electric motor (150, 250) disposed in the housing (137, 237), wherein the transmission (160, 260) is coupled on the drive side to the electric motor (150, 250) and the transmission (160, 260) is coupled on the output side to a second stabiliser element (115, 215). The invention is characterised by a transmission (260) which is arranged substantially within the electric motor. The invention also relates to the use of a roll stabiliser in a chassis on at least one axle of a motor vehicle.