Integrated Rotor Position Sensor Cover for Compact Motor Assembly
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Solution Overview
Problem
Existing rotor position sensors in electric motors require a large installation space and numerous components, leading to increased costs and complexity.
Innovation Solution
A rotor position sensor with an integrated sensor housing that doubles as a cover for the motor housing, incorporating coils, lines, and a control unit, and features such as a flange, seal, and cable bushing, reducing the need for separate components and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cover is used to close the motor housing and accommodate the rotor position sensor, then the rotor position sensor can be properly installed and sealed, but the installation space increases and the number of components increases
Solution Approach 1:
The patent combines the rotor position sensor housing with the motor housing cover into a single integrated component. The sensor housing forms part of the cover structure, eliminating the need for separate cover and sensor housing components. This merging reduces the total number of parts while maintaining the sealing function through integrated design features.
Solution Approach 2:
The cover structure is designed to serve multiple functions simultaneously: it closes the motor housing, accommodates the rotor position sensor, provides sealing through integrated seal elements, and maintains structural integrity. This multi-functionality eliminates the need for separate dedicated components for each function.
2Reliability
If a separate cover is used to close the motor housing, then the rotor position sensor can be accommodated, but the installation space (axial space) increases
Solution Approach 1:
The sensor housing is merged with the cover structure, allowing the sensor to be accommodated within the cover itself rather than requiring additional space. This integration eliminates the need for separate axial space for a dedicated sensor housing.
Solution Approach 2:
The rotor position sensor is nested within the cover structure, with the sensor housing forming part of the cover assembly. This nesting arrangement allows the sensor to be accommodated without increasing the overall installation space, as the sensor occupies space within the existing cover volume.
3Reliability
If multiple separate components are used for the rotor position sensor assembly, then each component can be optimized for its specific function, but the production costs increase
Solution Approach 1:
The cover and sensor housing are merged into a single integrated component that can be produced as one piece through injection molding. This eliminates the need for separate manufacturing processes and assembly operations for multiple components, reducing production costs while maintaining functional optimization through integrated design.
Solution Approach 2:
The integrated cover structure performs multiple functions (sealing, sensor accommodation, structural support) simultaneously, eliminating the need for multiple specialized components. This reduces the total number of parts that need to be manufactured, inventoried, and assembled, thereby reducing production costs.
4Adaptability or versatility
If multiple separate components are used for the rotor position sensor assembly, then each component can be independently designed, but the assembly process becomes more complex
Solution Approach 1:
The cover and sensor housing are merged into a single integrated component produced by injection molding, eliminating the need for separate assembly of these parts. This reduces the assembly process complexity while maintaining design flexibility through the molding process capabilities.
Solution Approach 2:
The integrated cover structure combines multiple functions into one component, reducing the number of assembly steps required. The single-component design eliminates the need for aligning and fastening multiple separate parts, simplifying the assembly process while maintaining design adaptability.
Data Source
AI summary
A rotor position sensor for a motor vehicle for sensing the rotational position of a rotor of an electric motor includes a sensor housing, in which the components of the rotor position sensor are accommodated. At least part of the sensor housing forms a cover for closing a motor housing of the electric motor.