Rotary Machine Casing with Metal-Plastic Flange Connection
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Solution Overview
Problem
Existing rotary electric machine casings are heavy and lack efficient EMC protection, while also requiring complex structures to support torque and cooling functions.
Innovation Solution
A casing design combining a metal inner casing part with a plastic outer casing part, featuring overlapping flanges for force transmission and a sandwich construction, along with air gaps and O-rings for tolerance compensation and sealing, to create a lightweight, sound-damping, and EMC-protected structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal casing is used to support torque and provide EMC protection, then strength and EMC protection are improved, but weight increases
Solution Approach 1:
The casing is divided into two functional parts: an inner metal casing part that encloses the stator and rotor to provide torque support and EMC protection, and an outer plastic casing part that provides structural protection and cooling functions. This segmentation allows each material to be used where it is most effective, reducing overall weight while maintaining strength.
Solution Approach 2:
The invention uses a composite structure combining metal and plastic materials in the casing. The metal inner casing part provides high strength and EMC protection, while the plastic outer casing part provides structural support and cooling functionality. This composite approach optimizes the weight-strength trade-off by using each material's advantageous properties.
2Object-affected harmful factors
If a metal casing is used for EMC protection, then electromagnetic shielding is improved, but sound damping capability deteriorates
Solution Approach 1:
The casing is segmented into an inner metal part for EMC shielding and an outer plastic part for noise damping. This allows the metal to provide electromagnetic protection while the plastic absorbs and dampens operational noises, addressing both harmful factors simultaneously.
Solution Approach 2:
The composite structure of metal and plastic in the casing combines the electromagnetic shielding properties of metal with the acoustic damping properties of plastic, creating a multi-functional casing that addresses both EMC protection and noise reduction requirements.
3Force
If flanges are used to connect inner and outer casing parts, then force transmission is improved, but manufacturing complexity increases
Solution Approach 1:
The connection points are designed by merging the inner and outer casing parts through integrated flange structures. The flanges are formed as integral parts of the respective casing components, and the connection points simultaneously provide structural attachment and torque transmission pathways, simplifying the overall design while maintaining force transmission capability.
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
The design achieves a lightweight, stable, and EMC-protected rotary electric machine casing that efficiently supports torque and cooling functions while minimizing manufacturing complexity and weight, ensuring effective force transmission and noise reduction.
Implementation Method 1
The outer casing part, which is made of a plastic, acts in a sound-damping manner
Implementation Method 2
The casing comprises at least one first O-ring between the outer casing part and the inner casing part in order to seal the cavity in a watertight manner
Implementation Method 3
at least one cavity between the outer casing part and the inner casing part for accommodating a cooling liquid
Implementation Method 4
A casing of this type is known for example from DE 10 2009 031 467 A1... the casing can form a coolant jacket for cooling the motor
Data Source
AI summary
A casing for a rotary electric machine and a rotating electric machine includes an inner casing part made of a metal or a metal alloy and which encloses a stator and a rotor of the rotary electric machine, an outer casing part made of plastic and which at least partially surrounds the inner casing part, and at least one connection point located between the inner casing part and the outer casing part and which mechanically connects the outer casing part to the inner casing part, wherein the at least one connection point has a first flange on the outer casing part and a second flange on the inner casing part.