Active Roll Stabilizer Motor Mounting for Accurate Rotor Sensing
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Solution Overview
Problem
Existing active roll stabilizers for motor vehicles face challenges in reliably transferring system loads to the actuator, leading to elastic deformation and potential interference with sensor measurements.
Innovation Solution
The active roll stabilizer design features a torsion bar divided into parts with an actuator between them, where the electric motor's housing is connected to the actuator housing for conjoint rotation only at one end, allowing the motor to support only its own torque and preventing system loads from affecting the motor housing, ensuring accurate rotor position detection and reduced noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor housing is rigidly connected to the actuator housing for conjoint rotation, then torque transmission is improved, but the sensor element is affected by system load causing measurement inaccuracy
Solution Approach 1:
The connection between motor housing and actuator housing is segmented into two distinct connection points: one end connected for conjoint rotation to transmit motor torque, and the other end deliberately left unconnected to prevent system load transmission. This segmentation allows independent optimization of torque transmission and sensor protection functions.
Solution Approach 2:
The sensor element (rotor position sensor) is extracted from the motor housing and mounted on the actuator housing instead. This relocation removes the sensor from the load-bearing motor housing structure, preventing system loads from affecting sensor measurements while maintaining accurate rotor position detection.
2Stability of the object's composition
If the motor housing supports system loads, then structural stability is improved, but elastic deformation occurs affecting sensor calibration
Solution Approach 1:
The actuator housing serves as an intermediary structure that receives the sensor element on one side while the motor housing provides torque transmission on the other. This intermediary arrangement allows the sensor to be supported by a structure (actuator housing) that does not experience the same elastic deformations from system loads, preserving calibration accuracy.
3Reliability
If a strong interference fit is used to connect motor and actuator housing, then torque transmission is improved, but noise increases
Solution Approach 1:
Different connection qualities are applied at different locations: a form-fitting connection with polygonal profiles provides reliable torque transmission at the primary connection point, while a weaker interference fit or clearance connection at the second end reduces noise generation. This local differentiation optimizes both torque transmission and acoustic performance.
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 design ensures reliable torque transmission and accurate measurement of the rotor position, reducing noise and allowing for a weaker interference fit, thereby enhancing the system's reliability and acoustic performance.
Implementation Method 1
an electric motor (7) are arranged in the actuator housing (5)... The motor shaft (10) transfers the motor torque to the input shaft of the transmission (6)
Implementation Method 2
the transmission, in particular formed as a planetary transmission (9), is connected to the other torsion bar part (3) for conjoint rotation on the output side
Data Source
AI summary
An active roll stabilizer includes a divided torsion bar (1) having torsion bar parts (2, 3) which are arranged one behind the other along a torsion bar axis. An actuator (4) for transmitting torsional torques to the torsion bar (1) is provided. An electric motor (7) and a transmission (6) connected to the electric motor (7) are arranged in an actuator housing (5). The actuator housing (5) is connected to the one torsion bar part (2) for conjoint rotation and the transmission (6) is connected, on the output side, to the other torsion bar part (3) for conjoint rotation. A motor housing (11) of the electric motor (7) is connected, by means of only one of the two axial ends of said motor housing, to the actuator housing (5) for conjoint rotation.