Steer-by-Wire Motor with Integrated Magnetic Gearing
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Solution Overview
Problem
Conventional feedback torque generators in steer by wire systems require complex and bulky arrangements of electric motors and gearboxes to provide high torque at low speeds, which is costly and inefficient.
Innovation Solution
An electromagnetic motor design featuring an inner stator with a controller-generated pattern of magnetic poles, an outer stator with alternating magnet poles, and an intermediate rotor with pole pieces that shape magnetic flux, allowing for high torque at low speeds through controlled magnetic gearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a step down gearbox is used to provide high torque at low speeds, then the required torque is achieved, but the system becomes complex and bulky
Solution Approach 1:
The patent merges the motor and gearbox into a single integrated unit. The motor's rotor is directly coupled to the output shaft, eliminating the need for a separate gearbox. The stator teeth are directly driven by the controller to produce the required torque at low speeds, combining the functions of motor and gear reduction in one component.
Solution Approach 2:
The patent replaces the mechanical gearbox with an electromagnetic field-based torque generation system. Instead of using mechanical gears to reduce speed and increase torque, the controller directly generates a pattern of magnetic poles that interact with the rotor to produce high torque at low speeds through electromagnetic interaction.
2Force
If a step down gearbox is used to provide high torque at low speeds, then the required torque is achieved, but the system becomes bulky
Solution Approach 1:
The motor and gearbox functions are merged into a single integrated structure. The rotor is directly coupled to the output shaft, and the stator teeth are directly driven by the controller, eliminating the need for separate gear components and reducing overall system volume.
Solution Approach 2:
The mechanical gearbox is replaced with an electromagnetic torque generation system that produces high torque at low speeds directly, eliminating the bulk associated with mechanical gear components while maintaining the required torque output.
3Force
If a separate motor and gearbox are used, then high torque at low speeds is achieved, but the cost increases
Solution Approach 1:
The patent combines the motor and gearbox into a single manufactured unit, reducing the number of parts that need to be produced, assembled, and quality-checked. This integration simplifies the manufacturing process and reduces overall production cost while maintaining the high torque capability.
Solution Approach 2:
By replacing the mechanical gearbox with an electromagnetic torque generation system, the patent reduces the number of mechanical components that require precision manufacturing and assembly, thereby lowering manufacturing costs while achieving the required torque output.
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
The motor provides high force density and torque at reduced speeds, simplifying the system by eliminating the need for a separate gearbox, thus reducing complexity and bulk while maintaining cost-effectiveness.
Implementation Method 1
an inner stator comprising a plurality of stator teeth, each surrounded by one or more turns of electrical wire, a controller which generates a set of currents that are applied to the phase windings of the inner stator to generate a pattern of magnetic poles spaced around the inner stator
Implementation Method 2
an intermediate rotor part that is located between the inner stator and the outer stator and comprises an array of pole pieces, in which the pole pieces of the rotor shape the magnetic flux acting between the two stators
Data Source
AI summary
An electromagnetic motor comprising an inner stator comprising a plurality of stator teeth, each surrounded by one or more turns of electrical wire, a controller which generates a set of currents that are applied to phase windings of the inner stator to generate a pattern of magnetic poles spaced around the inner stator, the spacing between the magnetic poles being larger than the spacing between adjacent teeth of the inner stator, an outer stator that is concentric with the inner stator and comprises an alternating set of magnet poles, the spacing between adjacent magnet poles being smaller than the spacing of the magnetic poles of a first array created by the controller, and an intermediate rotor part that is located between the inner stator and the outer stator and comprises an array of pole pieces, in which the pole pieces of the intermediate rotor part shape a magnetic flux acting between the inner and outer stators, and whereby in use the controller is arranged to control a torque applied to the rotor part by moving the pattern of magnetic poles of the inner stator around an axis of a torque generator.