Segmented Rotor Cores with Protrusions and Grooves for Torque
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Solution Overview
Problem
The torque of belt-driven starter generators (BSG) is limited due to spatial constraints and current limitations, making it difficult to increase the number of winding coils or current.
Innovation Solution
A rotor design featuring stacked first and second cores with protrusions and grooves allows for increased coil space factor and easier assembly, enabling more efficient winding and torque enhancement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of winding coils is increased to increase torque, then torque is improved, but spatial constraints prevent further increase in the number of coils
Solution Approach 1:
The rotor core is divided into multiple segments (first core and second core) that are stacked together. Each core has teeth with extensions that create additional winding spaces. This segmentation allows coils to be wound around multiple segments, effectively increasing the coil space factor and enabling more coils to be accommodated within the same radial space, thereby increasing torque without violating spatial constraints.
Solution Approach 2:
The invention utilizes the axial dimension by extending teeth in the axial direction to create additional winding spaces. Instead of only increasing radial space, the extensions protrude axially to provide extra volume for coil winding. This dimensional approach allows more coils to be fitted without increasing the overall radial footprint, resolving the contradiction between torque (requiring more coils) and spatial constraints.
2Area of stationary object
If complex rotor structures are used to increase coil space factor, then coil space is improved, but assembly difficulty increases
Solution Approach 1:
The rotor is segmented into multiple standardized cores that can be manufactured separately and then stacked. Each core has identical tooth extensions and winding spaces, allowing for modular assembly. The grooves and protrusions on the extensions provide alignment features that simplify the stacking process, making assembly easier despite the increased complexity of the overall structure.
Solution Approach 2:
The multiple cores are nested together in a stacked configuration, with each core containing winding spaces that accommodate coils. The extensions of the teeth create nested winding regions within the stacked cores. This nesting approach efficiently utilizes space while maintaining a relatively simple assembly process through standardized interfaces between cores.
3Power
If current is increased to increase torque, then torque is improved, but current limit prevents further increase
Solution Approach 1:
By dividing the rotor into multiple cores with additional winding spaces, the invention enables increased total coil turns. This allows torque to be increased through increased magnetic flux (more coils) rather than increased current, thereby avoiding the current limit constraint while still achieving higher torque output.
Data Source
AI summary
Provided is a rotor including the first extension includes a first protrusion disposed on the inner circumferential surface of the first extension, the first body includes a first groove formed in the outer circumferential surface of the first body, the second extension includes a second protrusion disposed on the inner circumferential surface of the second extension, the second body includes a second groove formed in the outer circumferential surface of the second body, the first body and the second body are stacked and coupled to each other, the first protrusion is disposed in the second groove, and the second protrusion is disposed in the first groove.