Shared-Core Rotary Transformer and Motor for Compact Sensor Assemblies
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Solution Overview
Problem
Existing rotary sensor assemblies for autonomous vehicles face challenges in efficiently transferring power, torque, and data through rotary joints, often requiring multiple components that can be costly, bulky, and prone to wear.
Innovation Solution
An integrated hybrid rotary sensor assembly that shares a magnetic core among the motor, rotary transformer, and RF communication link, reducing the number of components and enhancing manufacturing efficiency, cost-effectiveness, and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate motor and rotary transformer components are used, then power and torque can be provided to the rotating sensor assembly, but the number of components increases leading to higher cost, larger size, and reduced reliability
Solution Approach 1:
The patent combines the motor and rotary transformer into a single integrated assembly where the stator serves dual purposes: it acts as both the motor stator and the rotary transformer core. The rotor contains both the motor winding and the transformer winding, merging two separate components into one unified structure that provides both motor function and power transformation function simultaneously.
Solution Approach 2:
The stator is designed to perform multiple functions: it serves as the magnetic core for both the motor and the rotary transformer, and provides structural support for both windings. The rotor similarly serves dual purposes by containing both the motor winding and transformer winding, making the assembly multi-functional and reducing the overall component count.
2Ease of manufacture
If multiple separate components are used for motor and transformer functions, then torque and power transfer are achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
By merging the motor and rotary transformer into a single integrated assembly with shared stator and rotor components, the patent reduces the number of manufacturing steps and assembly operations required. The single stator and rotor can be manufactured as unified structures, eliminating the need to manufacture and assemble separate motor and transformer components.
3Volume of moving object
If separate motor and transformer assemblies are employed, then functional requirements are met, but the overall size and volume of the rotary mechanism increase
Solution Approach 1:
The patent implements a nested structure where the transformer winding is positioned within the rotor, surrounded by the motor winding. The stator serves as the outer structure containing both windings, creating a compact nested arrangement that maximizes space utilization and minimizes the overall volume of the rotary mechanism.
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 shared magnetic core configuration simplifies the assembly, reduces component failure rates, and lowers production costs while maintaining high reliability and efficient data transfer capabilities.
Implementation Method 1
a rotary transformer coil disposed on a first side of the stator... Each of the teeth has wire wound therealong
Implementation Method 2
The motor unit includes a ferrous stator and a rotor. The rotor encircles the stator and is configured to rotate about the axis.
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.