Motor Drive Shaft Lock With Integrated Sliding Brushes

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Solution Overview

Problem

Existing locking apparatuses for electric motor drive units in vehicles are inefficient in terms of component integration, structural space usage, and assembly complexity, and require high actuation forces for locking mechanisms.

Innovation Solution

A locking apparatus with a positive-locking element actuated by a resilient force transmission element, integrated with a housing and a transversely arranged electric drive, incorporating sliding brushes for remote excitation of a rotor, and a compact design that includes a position sensor for efficient commutation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate arrangement of contacting element with sliding brushes is provided for remote excitation, then reliable remote excitation is achieved, but device complexity and structural space requirements increase

Engineering Contradiction:

Improveremote excitation reliabilityVSAvoidcomponent integration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the contacting element with sliding brushes into the locking apparatus housing, merging previously separate components (locking mechanism and remote excitation system) into a single integrated structure. This reduces device complexity while maintaining reliable remote excitation functionality through the preserved sliding brush contact arrangement.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If high actuation forces are applied to the locking mechanism, then secure locking is achieved, but energy consumption and mechanical stress increase

Engineering Contradiction:

Improvelocking securityVSAvoidactuation energy

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The resilient force transmission element is pre-tensioned to store elastic energy before locking engagement. This preliminary action allows the locking mechanism to achieve secure locking with minimal additional actuation force, as the stored elastic energy automatically engages the positive-locking element with the shaft-side complement when the triggering condition is met.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The resilient force transmission element serves itself by automatically converting stored elastic energy into locking force. Once triggered, the pre-tensioned element self-activates to engage the locking mechanism without requiring continuous external actuation force, reducing energy consumption while maintaining reliable locking.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If multiple separate components are used for locking and remote excitation, then functional versatility is achieved, but assembly complexity and manufacturing cost increase

Engineering Contradiction:

Improvefunctional capabilityVSAvoidassembly complexity

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The locking apparatus housing serves multiple functions: it houses the locking mechanism, integrates the contacting element with sliding brushes for remote excitation, and provides structural support. This multi-functional design consolidates previously separate components into a single universal structure, reducing assembly complexity and manufacturing cost while preserving all necessary functional capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 provides a compact, cost-effective locking mechanism that simplifies assembly, reduces structural space requirements, and enables energy-efficient locking with minimal actuation forces, while ensuring reliable shaft locking and emergency locking in case of motor failure.

Implementation Method 1

A resilient force transmission element is in this instance intended to be understood to be a mechanical energy store for resilient pretensioning/tensioning of the actuatable positive-locking element with respect to the shaft-side complement

Methodology Applied

Scientific EffectElastic energy storage: Elasticity

Implementation Method 2

a separate arrangement of contacting element having at least two sliding brushes for remote excitation of a rotor, which is connected to the shaft, of a synchronous machine of the electric motor drive unit

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20260016055A1Locking device, electric motor drive unit, and vehicle

Publication Date: 2026.01.15 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A locking apparatus for an electric motor drive unit having a locking mechanism for locking a lockable shaft of the electric motor drive unit and an electric drive for actuating the locking mechanism which in addition to the locking mechanism is received by a housing of the locking apparatus. A separate arrangement of contacting elements having at least two sliding brushes for remote excitation of a rotor, which is connected to the shaft, of a synchronous machine of the electric motor drive unit is received by the locking apparatus housing.