Electric Machine Shaft Securing With Deformed Groove Locking

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Solution Overview

Problem

Existing shaft systems for electric machines require complex manufacturing processes and assembly devices to achieve axial and rotational securing, leading to high costs.

Innovation Solution

A shaft system with a shaft having peripheral grooves and securing devices that form interlocking connections through deformation into the grooves, providing axial stops and rotational securing with minimal manufacturing effort and cost.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional axial stops (shaft shoulders, shaft flanges, shaft nuts, snap rings) are used, then axial securing is achieved, but manufacturing complexity and assembly device requirements increase

Engineering Contradiction:

Improveaxial securingVSAvoidassembly device complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines axial securing and rotational securing functions into a single integrated solution. The securing device includes both axial stops (first and second) and interlocking connections that prevent rotation, eliminating the need for separate axial stops and rotational securing mechanisms. This merging reduces the number of components and simplifies assembly operations.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The securing device serves multiple functions simultaneously: it provides axial positioning through the first and second axial stops, prevents rotation through interlocking connections with the groove, and transmits forces bidirectionally in the circumferential direction. This multi-functionality replaces what would traditionally require multiple separate components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional rotational securing mechanisms (transverse press fits, grooves, profiled shafts, splines) are implemented, then rotational securing is achieved, but manufacturing effort and cost increase

Engineering Contradiction:

Improverotational securingVSAvoidmanufacturing effort

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent integrates rotational securing (via interlocking connections in the groove) with axial securing (via axial stops) into a single securing device. This combination means that while rotational securing is achieved, the manufacturing effort is reduced because the same device also provides axial positioning, eliminating the need for separate rotational securing components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The securing device is designed to perform multiple functions: axial positioning, rotational securing, and force transmission. By making the device universal, the manufacturing process is simplified as fewer different types of components need to be produced and assembled.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If high deformation forces are applied during assembly, then securing is achieved, but material expansion and potential damage increase

Engineering Contradiction:

Improvesecuring strengthVSAvoidmaterial integrity

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent employs multiple radial deformations distributed around the circumference rather than a single excessive deformation. This distributes the stress and material expansion across multiple points, preventing localized damage while achieving the necessary securing strength. The deformations are radial and partial, not complete circumferential deformation.

Inventive Principle:

Principle #16Partial or excessive action

Solution Approach 2:

The patent transitions from axial deformation (which would cause significant material expansion in the axial direction) to radial deformations (which distribute material expansion in the radial direction). This dimensional change reduces the impact on axial positioning and minimizes potential damage to the shaft and securing device.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution enables simple, cost-effective axial and rotational securing of shaft components with precise positioning and compensation for component tolerances and thermal expansion, reducing assembly forces and enhancing operational stability.

Implementation Method 1

The interlocking connection is implemented by a deformation of the securing device into the groove

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

an axial material expansion at the end faces of the securing device is minimized and evenly distributed

Methodology Applied

Scientific EffectMaterial expansion: Thermal Expansion

Data Source

PatentUS12603545B2Axially securing a shaft component of an electric machine

Publication Date: 2026.04.14 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A shaft system including a shaft having a peripheral groove extending in the circumferential direction, and further including a securing device as well as an interlocking connection by a deformation of the securing device into the groove. The securing device forms a first axial stop for a shaft component. The securing device includes a second axial stop. Also disclosed are an electric machine having the shaft system as well as a process for manufacturing the shaft system.