Shared-Core Rotary Assembly for Power, Torque, and Data Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Rotating sensor assemblies face challenges in effectively transferring power, torque, and data through rotary joints due to the complexity and reliability issues of separate components like slip rings and motors, which can lead to increased costs and maintenance needs.
Innovation Solution
An integrated hybrid rotary sensor assembly that shares a magnetic core for the motor, rotary transformer, and RF communication link, reducing the number of components and simplifying the structure, thereby enhancing reliability and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate slip ring and motor components are used to provide power and torque to rotating sensor assembly, then power and torque transfer is achieved, but component wear and reliability decrease
Solution Approach 1:
The patent combines the motor and rotary transformer into a single integrated assembly where the motor stator and transformer stator share a common magnetic core. This merging eliminates the need for separate slip rings and multiple independent components, directly reducing component count and improving reliability while maintaining power and torque transfer functions.
Solution Approach 2:
The shared magnetic core serves multiple functions simultaneously: it acts as the magnetic path for motor operation, the transformer core for power transfer, and provides structural support for both windings. This multi-functionality reduces the overall component count while achieving power transfer, torque generation, and rotational movement in a single integrated system.
2Power
If separate motor and rotary transformer are used to produce torque and transfer power, then torque and power transfer are achieved, but component count and cost increase
Solution Approach 1:
The motor and rotary transformer are merged into a single integrated assembly with shared magnetic core, stator structure, and winding arrangements. The motor windings and transformer windings are both wound on the same magnetic core teeth, eliminating the need for separate motor and transformer components while maintaining full power transfer capability through the shared magnetic path.
Solution Approach 2:
The shared magnetic core and stator structure perform dual functions: generating motor torque through interaction with rotor magnets and transferring power to the rotating assembly through transformer induction. This multi-functionality allows a single component to replace what would traditionally require separate motor and transformer units.
3Adaptability or versatility
If multiple separate components are used for motor, transformer, and communication link, then functional requirements are met, but manufacturing complexity and cost increase
Solution Approach 1:
The motor, rotary transformer, and RF communication link are merged into a single integrated assembly. The RF communication element is positioned within the same housing and shares the magnetic core structure with the motor and transformer, allowing all three functions to be manufactured and assembled as one unit rather than three separate components.
Solution Approach 2:
The shared magnetic core structure provides a universal platform that supports motor operation, power transformation, and RF communication functions. The stator housing serves as a common structural element for all three subsystems, simplifying manufacturing by allowing simultaneous production of multiple functions in a single assembly process.
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 integrated architecture provides a streamlined and reliable solution for power, torque, and data transfer, reducing component count, costs, and improving system reliability, while enabling efficient communication and operation of rotatable sensors like lidar, radar, and cameras in autonomous vehicles.
Implementation Method 1
The motor unit includes a ferrous stator and a rotor. The rotor encircles the stator and is configured to rotate about the axis. Each of the teeth has wire wound therealong.
Implementation Method 2
The first side of the stator includes a rotary transformer coil disposed thereon.
Implementation Method 3
A radio frequency (RF) communication element is disposed on the stator adjacent to the central opening. The RF communication element is configured to transmit or receive RF signals used for data communication by the sensor unit.
Data Source
AI summary
An integrated hybrid rotary assembly is configured to provide power, torque and bi-directional communication to a rotatable sensor, such as a lidar, radar or optical sensor. A common ferrite core is shared by a motor, rotary transformer and radio frequency communication link. This hybrid configuration reduces cost, simplifies the manufacturing process, and can improve system reliability by employing a minimum number of parts. The assembly can be integrated with the sensor unit, which may be used in vehicles and other systems.