Rotary Electric Machine Linking Plate Load Absorption
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Solution Overview
Problem
Conventional hybrid vehicle mechanical power transmitting apparatuses face increased loads on the torque converter due to its direct connection with the engine and motor-generator, leading to potential damage and enlarged rotor dimensions when the torque converter is housed inside the rotor.
Innovation Solution
A rotary electric machine design featuring a rotor boss with a cylindrical rotor ring, annular mounting portion, and a linking plate with a curved shape and reducing thickness, which absorbs engine loads and disperses stress, allowing the torque converter to be external without increasing rotor dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the torque converter is housed inside the rotor of the motor-generator, then the direct distance from the engine to the torque converter is shortened and loads on the torque converter are reduced, but the radial dimensions of the rotor are increased
Solution Approach 1:
The patent introduces a rotor boss as an intermediary component between the rotor and the torque converter. This rotor boss includes a linking plate with varying thickness that acts as a mediator to transmit and distribute loads from the rotor to the torque converter, allowing the torque converter to be positioned outside the rotor while maintaining reduced load transmission.
Solution Approach 2:
The patent changes the spatial arrangement from housing the torque converter inside the rotor (radial positioning) to positioning it outside the rotor (axial positioning). This dimensional change allows the torque converter to be relocated without increasing the radial dimensions of the rotor, while the rotor boss with its linking plate structure manages the load transmission in this new configuration.
2Device complexity
If the engine, motor-generator, and torque converter are disposed in series in a straight line, then the configuration is simplified, but the direct distance from the engine to the torque converter is long and bending moments increase
Solution Approach 1:
The rotor boss serves as an intermediary structural element that modifies the load transmission path between the engine and torque converter. The linking plate within the rotor boss distributes forces and reduces bending moments by creating a more favorable structural configuration, allowing the series arrangement to be maintained while reducing harmful loads.
3Ease of manufacture
If the linking plate has uniform thickness, then manufacturing is simplified, but stress dispersion and load absorption capabilities are reduced
Solution Approach 1:
The linking plate is designed with non-uniform thickness, where the thickness varies at different locations to optimize stress distribution. The thicker regions provide structural strength and stress dispersion capability, while thinner regions reduce overall mass. This local quality variation allows the linking plate to effectively absorb and distribute loads while remaining manufacturable.
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 effectively reduces loads on the torque converter, suppresses damage, and maintains compact rotor dimensions by using the linking plate's deformation to absorb engine loads and dispersing stress, thereby eliminating the need to house the torque converter inside the rotor.
Implementation Method 1
the thinnest portion of the linking plate deforms and absorbs the loads in question
Implementation Method 2
the magnets being fixed to the rotor core using an adhesive
Data Source
AI summary
The rotor of the rotary electric machine according to the present invention includes: a cylindrical rotor core; magnets that are respectively housed in a plurality of magnet housing apertures that are formed circumferentially so as to pass axially through an outer circumferential side of the rotor core; and a rotor boss that includes: a cylindrical rotor ring that holds the rotor core; an annular mounting portion that is linked to the crankshaft so as to be disposed coaxially at a first axial end inside the rotor ring; and a linking plate that links the rotor ring and the mounting portion, and the linking plate is formed so as to have a curved shape that is convex toward a second axial end of the rotor boss, and has a thickness that reduces continuously from a radially inner side toward a radially outer side.