Torque Arm with Meandering Ribs for Angle Sensor Mounting
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Solution Overview
Problem
Existing electric motor designs face challenges in achieving simplicity and cost-effectiveness while maintaining precise angular position detection and torsional rigidity, particularly in compensating for manufacturing tolerances and radial forces.
Innovation Solution
The electric motor incorporates a fan cover and rotor shaft with an angle sensor mounted rotatably, utilizing a torque arm with inner and outer rings connected via webs, allowing for elastic compensation of radial forces and maintaining high torsional rigidity in the circumferential direction, enabling easy assembly and production with inexpensive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid connection is used to connect the angle sensor housing to the fan cover, then torsional rigidity is improved, but manufacturing tolerances cannot be compensated
Solution Approach 1:
The torque arm transitions from a rigid connection to a dynamic, flexible connection that can adapt to manufacturing tolerances. The flexible structure allows for elastic deformation in radial and axial directions while maintaining torsional rigidity for accurate angle detection.
Solution Approach 2:
The torque arm's flexibility parameters are optimized to provide the right balance: soft in radial and axial directions for tolerance compensation, but stiff in the circumferential direction for maintaining torsional rigidity and accurate angle sensor readings.
2Ease of manufacture
If a flexible connection is used to compensate for tolerances, then ease of manufacture is improved, but torsional rigidity deteriorates
Solution Approach 1:
The torque arm exhibits different mechanical properties in different directions: flexible in radial and axial directions for ease of manufacture and tolerance compensation, but rigid in the circumferential direction for maintaining torsional stiffness. This directional differentiation of mechanical properties resolves the contradiction.
3Measurement precision
If the angle sensor housing is rigidly connected to the fan cover, then measurement precision is improved, but device complexity increases due to special torque supports
Solution Approach 1:
The torque arm's flexible structure automatically compensates for manufacturing tolerances through its own elastic deformation, eliminating the need for additional adjustment mechanisms or complex torque supports. The structure serves its own alignment and tolerance compensation functions.
4Device complexity
If radial forces are not compensated, then device complexity is reduced, but measurement precision deteriorates due to reaction torques
Solution Approach 1:
The torque arm acts as an intermediary element between the angle sensor housing and the fan cover. It mediates the transmission of forces and torques, allowing radial forces to be absorbed elastically while transmitting only the necessary rotational position information to the angle sensor, thereby protecting measurement precision.
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 effectively compensates for manufacturing tolerances and radial forces, achieving high torsional rigidity and efficient damping of vibrations, while allowing for accurate angle detection with reduced production complexity and cost.
Implementation Method 1
the outer ring is connected to an inner ring via inner webs, wherein the outer ring is deflected off-center relative to the inner ring in a radially directed manner, by means of which radial forces can be absorbed elastically
Implementation Method 2
an angle sensor, wherein a housing of the angle sensor is connected to a torque arm which is connected to the fan cover
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to an electric motor having a fan guard (9) and rotor shaft (5) mounted rotatably relative to the fan guard (9) and angle sensor (2), a housing of the angle sensor (2) being connected to a torque support (1) which is connected to the fan guard (9), the torque support (1) having ribs (21, 24) that are shaped in a meandering manner.