Starter Ring Gear and Transmission Coupler Layout for Dust-Sealed E-Machines
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Solution Overview
Problem
Existing electric machine designs integrating starter motors with flywheels face limitations in flexibility and size due to the fixed position of the starter motor relative to the flywheel, and they struggle with dust accumulation from internal sources, which affects efficiency and reliability.
Innovation Solution
The electric machine assembly includes a stator, a rotor, a starter ring gear component fixedly coupled with the rotor, and a transmission coupler fixedly coupled with the rotor on the opposite side of the stator. Dynamic seals are used between the starter ring gear and the stator, and between the transmission coupler and the stator, along with a sealing shield and a restriction channel with magnets to manage dust and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the starter motor is positioned adjacent to the starter ring gear on the outer periphery of the flywheel, then the starter motor can provide initial rotational power to the flywheel, but the position and location of the starter motor is limited and the overall size of the electric machine increases
Solution Approach 1:
The starter ring gear is separated from the flywheel into a distinct component. The starter ring gear component can be independently positioned and coupled to the rotor, while the flywheel remains separate. This segmentation allows the starter motor to be positioned independently from the flywheel, providing design flexibility while maintaining the starter function.
Solution Approach 2:
The starter ring gear is positioned on a first side of the stator while the flywheel is positioned on a second side of the stator, utilizing the axial dimension. This dimensional separation allows both components to coexist without spatial interference, enabling independent positioning and reducing overall machine size.
2Device complexity
If the starter ring gear is integrated with the flywheel, then the structure is simplified, but dust from internal sources accumulates within the electric machine affecting efficiency and reliability
Solution Approach 1:
The starter ring gear and flywheel are segmented into separate components with distinct positioning. This separation creates independent sealing zones that can be individually protected with dynamic seals, preventing dust accumulation in critical areas while maintaining structural efficiency.
Solution Approach 2:
Dynamic seals are introduced as intermediary elements between the starter ring gear component and stator, and between the flywheel and stator. These seals act as barriers that prevent dust from internal sources from entering critical areas, protecting the system while allowing the simplified integrated structure to remain.
3Object-affected harmful factors
If dust covers only prevent dust from outside the vehicle, then external dust is blocked, but dust from internal sources such as engine or transmission can still enter the electric machine
Solution Approach 1:
Dynamic seals serve as intermediary barriers positioned at the interfaces between the starter ring gear component/flywheel and the stator. These seals specifically address internal dust sources by creating sealed boundaries that prevent dust from the engine or transmission sides from entering the electric machine, complementing the external dust protection.
Solution Approach 2:
Dynamic seals are selectively positioned at specific locations where internal dust sources can penetrate - namely between the starter ring gear component and stator, and between the flywheel and stator. This localized sealing approach targets internal dust prevention without compromising overall system openness for necessary operations.
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 flexibility in electric motor implementation by allowing independent positioning of the starter motor and flywheel, reduces dust accumulation from both external and internal sources, and improves the overall efficiency and reliability of the electric machine.
Implementation Method 1
a first dynamic seal disposed between the starter ring gear component and the stator on the first side of the stator and a second dynamic seal disposed between the transmission coupler and the stator on the second side of the stator
Implementation Method 2
a restriction channel at least partially defined by the starter ring gear component and the housing. The restriction channel retrains dust and debris particles therein
Data Source
AI summary
Electric machine assemblies are disclosed. The electric machine assembly includes a stator, a rotor movably coupled with the stator, a starter ring gear component fixedly coupled with the rotor on a first side of the stator, and a transmission coupler fixedly coupled with the rotor on a second side of the stator opposite from the first side. Further disclosed are engine systems and methods of assembling the same, where the engine system includes an engine block with a crankshaft, as well as the electric machine assembly operatively coupled with the engine block such that the starter ring gear component is fixedly coupled with the crankshaft and the rotor on a first side of the stator.