Rotor Grounding Contact Access for Corrosion-Resistant Service
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Solution Overview
Problem
Existing grounding contact systems for electric machine rotors in motor vehicles face issues with corrosion and wear, requiring frequent inspection and replacement, which is time-consuming and often necessitates opening the housing for maintenance.
Innovation Solution
A grounding contact system where a closure element is removably attached to the rotor, allowing access without opening the housing, featuring a non-rolling abutting contact with axial pressure and a wear-resistant design, including a carbon pin and elastic element to minimize friction and facilitate easy inspection and replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a roller bearing is used for the grounding contact, then electrical current conduction is achieved, but electrical corrosion occurs and reliability deteriorates
Solution Approach 1:
The grounding contact is designed as a consumable component with a service life shorter than the housing, intentionally replaceable without housing disassembly. This resolves the contradiction by accepting controlled replacement of the grounding contact (cheap, short-living object) to prevent corrosion damage to the entire system, thereby maintaining overall reliability.
2Ease of repair
If the housing is opened for grounding contact maintenance, then inspection and replacement are possible, but maintenance time and complexity increase
Solution Approach 1:
The housing is segmented with a dedicated access opening that provides direct access to the grounding contact. This segmentation allows maintenance personnel to service the grounding contact independently without opening the entire housing, thereby improving ease of repair while minimizing loss of time.
Solution Approach 2:
A closure element serves as an intermediary component that can be removed to access the grounding contact. This mediator provides a convenient access path through the housing wall, enabling quick inspection and replacement of the grounding contact without time-consuming complete housing disassembly.
3Ease of operation
If a closure element is removably attached to provide access, then serviceability improves, but device complexity increases
Solution Approach 1:
The closure element is designed to serve multiple functions: it closes the access opening in the housing, provides structural support for the grounding contact, and can be removed for maintenance access. This multi-functionality improves ease of operation while minimizing the increase in device complexity by combining several functions into a single component.
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 enhances the serviceability of the grounding contact, reduces the risk of electrical corrosion, and allows for maintenance without disassembling the electric machine, making it suitable for high-loaded applications.
Implementation Method 1
The elastic element can have a wave spring shape
Implementation Method 2
The elastic element can have a wave spring shape
Data Source
AI summary
An electric machine (120) has a housing (225) and a rotor (205), which is mounted in the housing (225) for rotation about a rotational axis (215). In the housing (225), a recess (230) is provided at one axial end of the rotor (205), in which a closure element (235) is removably attached. A grounding contact (280) is arranged axially between the closure element (235) and the rotor (205).