Integrated Starter Generator Housing with Embedded Electronics
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Solution Overview
Problem
Conventional integrated starter generators (ISGs) face challenges due to bulky, inflexible, and heavy cabling for high current transmission, which introduces electromagnetic compatibility (EMC) issues and electrical losses, and require complex electronics and additional components, hindering their adoption despite their fuel-saving and emission-reducing benefits.
Innovation Solution
The integration of control electronics within the housing of the ISG, along with a high current terminal featuring a brass rod with a rubber coating and stepped formations for sealing, eliminates the need for separate cabling and reduces EMC by utilizing the housing as a Faraday cage, and simplifies manufacturing by eliminating additional sealing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If control electronics are placed in a separate control unit outside the housing, then the housing design is simpler, but bulky cabling is required to transmit high currents which causes EMC issues and electrical losses
Solution Approach 1:
The control electronics are integrated directly into the housing structure, merging previously separate components (control unit and housing) into a single unified structure. This eliminates the need for external cabling and reduces electrical losses while maintaining housing design simplicity through the unified integration approach.
Solution Approach 2:
The housing itself acts as an intermediary structure that incorporates the control electronics, serving multiple functions simultaneously: structural housing, EMC shielding, and control electronics mounting platform. This eliminates the need for separate cabling infrastructure.
2Device complexity
If control electronics are placed in a separate control unit outside the housing, then the housing design is simpler, but the cabling presents significant EMC challenges due to rapidly-switched high currents
Solution Approach 1:
By merging the control electronics with the housing into a single integrated structure, the patent eliminates external cabling that causes EMC issues. The integration ensures that high-current switching occurs within the shielded housing environment, preventing EMC problems.
Solution Approach 2:
The conductive housing material, which could potentially be susceptible to EMC interference, is instead utilized as an active EMC shield. The housing's conductive properties are converted into a benefit by creating a Faraday cage effect that protects the integrated control electronics from electromagnetic interference.
3Power
If the ISG requires complex electronics and additional components for high current switching, then the starting and generation functions are more capable, but the device becomes more complex and harder to manufacture
Solution Approach 1:
The patent merges the high-current switching electronics with the housing structure, allowing complex power management functionality to be integrated within the existing housing framework. This reduces overall device complexity by eliminating separate control units and extensive cabling infrastructure.
Solution Approach 2:
The housing is designed to serve multiple functions simultaneously: structural containment, EMC shielding, and as the mounting platform for control electronics. This multi-functionality reduces the need for additional dedicated components and simplifies the overall device architecture.
4Volume of moving object
If the ISG is designed to be compact to reduce engine bay space, then space utilization is improved, but heat dissipation and component layout become more challenging
Solution Approach 1:
By integrating control electronics directly into the housing, the patent reduces the total system volume occupied by the ISG assembly. The elimination of external control units and cabling infrastructure allows for a more compact overall design while maintaining adequate thermal management capabilities within the consolidated structure.
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 solution reduces cabling needs, minimizes electrical losses, enhances EMC shielding, and simplifies manufacturing, leading to a more compact, efficient, and reliable ISG system that can efficiently switch between starter and generator modes while reducing fuel consumption and emissions.
Implementation Method 1
the housing is typically manufactured from an electrically conductive material such as aluminum, the EMC generated by the switching currents is further shielded and contained by the well known Faraday-cage effect
Implementation Method 2
a rubber coating bonded to the brass rod, the rubber coating being located between the brass rod and the edge of the aperture and arranged to act as an electrical insulator to insulate the rod from the device housing
Data Source
AI summary
An integrated starter generator device comprising a housing, a stator and a rotor contained within the housing, the device further comprising control electronics operable to configure the device as either a starter or generator and contained entirely within the housing. The device may include a high current terminal having brass and rubber bonded together. The rubber forms both a sealing and an insulating function.