Starter-Generator Power Electronics Unit Installation
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Solution Overview
Problem
Existing starter-generator systems face challenges in efficient installation and sealing processes, particularly with the power electronics unit and resolver components, which can lead to mechanical and electrical connectivity issues.
Innovation Solution
A starter-generator module design that includes a bulkhead wall, module housing, e-motor stator, e-motor rotor, and power electronics unit, with specific features such as dynamic dry seals, removable panel doors, and a method for installing these components onto an internal combustion engine, ensuring secure mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotor carrier is fixed to the crankshaft through multiple holes and fasteners, then the mechanical connection strength is improved, but the installation complexity and time increase
Solution Approach 1:
The rotor carrier is divided into segments that can be assembled separately and then quickly connected to the crankshaft, reducing the number of fastening operations required while maintaining structural integrity
Solution Approach 2:
The rotor carrier holes and fastener positions are pre-aligned and pre-positioned during manufacturing, allowing for rapid installation without requiring complex alignment procedures during the installation process
2Reliability
If the power electronics unit covers the first opening in the module housing, then the electrical connection reliability is improved, but the accessibility for installation and maintenance deteriorates
Solution Approach 1:
A removable access panel or intermediate cover is introduced between the power electronics unit and the external environment, allowing technicians to access electrical connections for installation and maintenance while the power electronics unit remains securely covered during operation
Solution Approach 2:
The cover structure is made dynamically configurable, allowing it to be in a closed state during operation for reliability and an open state during maintenance for accessibility, transitioning between states as needed
3Ease of repair
If the AC electrical leads are removably connected between the e-motor stator and power electronics unit, then the ease of repair and replacement is improved, but the risk of connection failures increases
Solution Approach 1:
Redundant connection paths or backup connection mechanisms are built into the electrical lead system, providing a fail-safe that maintains electrical connectivity even if one connection point fails or becomes disconnected
Solution Approach 2:
The mechanical removable connection is supplemented or replaced with a more reliable connection mechanism such as a welded joint, brazed connection, or interference-fit connector that maintains permanent electrical continuity while still allowing for component replacement at the component level
Data Source
AI summary
A starter-generator module for a vehicle includes a bulkhead wall, a module housing fixed to the bulkhead wall, an e-motor stator fixed to the module housing, an e-motor rotor disposed radially inside of the e-motor stator, and a power electronics unit fixed to the module housing. The module housing has a first opening and the power electronics unit covers the first opening. The e-motor rotor has a rotor carrier arranged for fixing to a crankshaft of the internal combustion engine. In an example embodiment, the rotor carrier includes holes arranged for receiving respective fasteners for fixing the rotor carrier to an engine crankshaft, and a bolt circle diameter of the holes is less than an inside diameter of the first opening. In an example embodiment, the rotor carrier is fixed to a crankshaft by a bolt, and the first opening is arranged for receiving a tool to secure the bolt.