Stacked Rotor Design for BSG Torque Enhancement
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Solution Overview
Problem
In Belt Driven Starter Generators (BSG), there is a spatial restriction and torque limit due to the high number of wound coils and current limitations, making it difficult to increase motor torque.
Innovation Solution
A rotor design with stacked rotor bodies and teeth, where coils are wound around the teeth with guide parts on insulators to increase the space factor for coil assembly, allowing for easier winding and reduced coil consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the number of wound coils is increased to increase motor torque, then motor torque is improved, but spatial restriction is exceeded and device complexity increases
Solution Approach 1:
The rotor is divided into a first rotor and a second rotor that are stacked and coupled together. Each rotor has its own set of teeth and wound coils, allowing the motor to achieve higher torque without increasing the complexity of a single rotor structure. The segmentation enables independent optimization of each rotor's coil winding space.
Solution Approach 2:
The patent transitions from a single-planar rotor design to a three-dimensional stacked rotor configuration. By stacking the first and second rotors axially and coupling them together, the design utilizes the axial dimension to increase the effective winding space for coils, thereby increasing torque without exceeding radial or circumferential spatial restrictions.
2Force
If the current is increased to increase motor torque, then motor torque is improved, but current limitations are reached
Solution Approach 1:
The motor torque is increased by segmenting the rotor into multiple rotors, each contributing to the total torque output. This allows the system to achieve higher torque through increased magnetic interaction area rather than by increasing current beyond limitation thresholds.
Solution Approach 2:
The patent employs a composite rotor structure with multiple rotors stacked together, creating a composite electromagnetic system. This composite structure increases the effective active area for magnetic field interaction, enabling torque enhancement through structural composition rather than current increase.
3Force
If more coils are wound to increase torque, then motor torque is improved, but assembly difficulty increases and manufacturing precision requirements increase
Solution Approach 1:
The rotor assembly is segmented into separate first and second rotors that can be manufactured and assembled independently. Each rotor has its own teeth and coil windings, simplifying the manufacturing process for each component while achieving the cumulative torque effect of having more coils in the overall assembly.
Solution Approach 2:
The teeth and coil windings are pre-assembled on each rotor before the final stacking and coupling operation. This preliminary assembly allows for quality control and adjustment at the component level, reducing the overall assembly difficulty compared to attempting to assemble all coils and teeth in a single complex operation.
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
This design enhances the space factor for coil winding, simplifies the winding structure, and increases torque by providing a broader winding space, while securely supporting the coils and reducing the amount of material needed.
Implementation Method 1
a rotor wound synchronous type motor is a motor where a coil is wound on a protruder protrusively formed on an outer circumferential surface of a rotor
Implementation Method 2
the alternator is configured in such a fashion that a rotor is rotated to generate an AC (Alternating Current) power which then charges a battery using a rectifying device while the alternator is connected to a driving part of an engine to form a magnetic field through a driving force of the engine
Data Source
AI summary
A rotor comprises: a first motor which comprises a first rotor body and a plurality of first teeth formed on an outer circumferential surface of the first rotor body; a second rotor which comprises a second rotor body stacked on and coupled to the first rotor body and a plurality of second teeth formed on an outer circumferential surface of the second rotor body; a first coil which is wound around the first teeth; a second coil which is wound around the second teeth; a first insulator which is disposed between the first teeth and the first coil; and a second insulator which is disposed between the second teeth and the second coil.