Stator Mounting Device for Hybrid Drive Assembly
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Solution Overview
Problem
Existing assembly methods for hybrid drive modules face challenges in reliably and efficiently inserting the stator of an electrical machine into a bell-shaped transmission housing, especially after the rotor has been connected to the transmission input shaft, requiring precise alignment and secure fastening.
Innovation Solution
An assembly device featuring inner and outer guide elements with a radially extending connecting element, including adjustable slides and centering pins, allows for form-fitting engagement with the rotor hub, transmission input shaft, and transmission housing, enabling precise positioning and secure fastening of the stator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the stator is inserted into the bell-shaped gearbox housing after the rotor has been connected to the input shaft, then the hybrid drive module achieves a compact arrangement, but precise alignment and secure fastening of the stator becomes difficult
Solution Approach 1:
The mounting device is prepared in advance with inner and outer guide elements that define the precise alignment path. The inner guide element is positioned to engage the rotor hub, while the outer guide element engages the gearbox housing, establishing the correct stator position before insertion occurs. This preliminary setup ensures that when the stator is inserted, it automatically achieves the required alignment precision.
Solution Approach 2:
The mounting device acts as an intermediary tool between the stator and the gearbox housing. It includes guide elements that interface with both the rotor hub (inner guide) and the gearbox housing (outer guide), mediating the insertion process to ensure precise alignment. The mounting device transfers the alignment requirements from the final assembly configuration to the insertion operation.
2Volume of moving object
If the stator is inserted after rotor assembly, then space utilization is improved, but the complexity of the mounting process increases
Solution Approach 1:
The mounting device is segmented into distinct functional components: an inner guide element for engaging the rotor hub, an outer guide element for engaging the gearbox housing, and a mounting element for securing the stator. This segmentation allows each component to perform its specific function independently, simplifying the overall mounting process despite the complex sequence of operations required.
Solution Approach 2:
The mounting device is designed as a multi-functional tool that performs multiple operations: it centers the rotor, guides the stator insertion, ensures proper alignment, and facilitates secure fastening. By combining these functions into a single device, the patent reduces the number of separate tools and steps required, thereby managing the complexity of the mounting process.
3Manufacturing precision
If guide elements are used for precise positioning, then alignment accuracy is improved, but the device complexity increases
Solution Approach 1:
The inner guide element is nested within or in close proximity to the outer guide element, with both elements working together in a hierarchical arrangement. The inner guide element engages the rotor hub while the outer guide element engages the gearbox housing, creating a nested guiding system that achieves precise alignment through the coordinated action of multiple guide elements rather than a single complex mechanism.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A mounting device (29) is provided for inserting a stator (4) of an electric machine (3) into a bell-shaped gearbox housing (1), wherein the electric machine (3) is part of a hybrid drive module (2) and a rotor (5) of the electric machine (3) is at least indirectly connected to a gearbox input shaft (6) via a rotor carrier (9) and a rotor hub (9a) and its stator (4), extending concentrically to the rotor (5) and radially surrounding it, can be attached to the gearbox housing (1).To create an assembly device that enables the reliable assembly of the stator after a key component of the hybrid drive module connected to the rotor has been positioned within the gearbox housing, the assembly device (29) shall have an inner guide element (38) designed to be positively guided against the rotor hub (9a) or the gearbox input shaft (6) that receives the rotor hub (9a). The assembly device (29) shall also have an outer guide element (37) to be positively guided against the gearbox housing (1).The two guide elements (37 and 38), which are radially spaced apart from each other, are fixed to each other via at least one radially extending connecting element (39), wherein at least one slide (30) is guided longitudinally displaceably in the connecting element (39), which has two slide parts (31 and 32) adjustable to each other, of which a first radially outer slide part (31) is provided for a positive engagement on the outer circumference of the stator (4) and a second radially inner slide part (32) is provided for an engagement on an end face of the stator (4).