Vernier Motor Roll Stabilizer for Compact Vehicle Actuation
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Solution Overview
Problem
Existing active roll stabilizers for motor vehicles require large assembly space due to the size and weight of conventional electric motors and transmissions, which limits their compactness and efficiency, particularly in applications like rear axle steering or electric axle drives.
Innovation Solution
The use of a Vernier motor, which is smaller, lighter, and more power-efficient than conventional electric motors, is integrated with a compact transmission within the actuator housing, allowing for coaxial positioning and reducing the overall size and weight of the roll stabilizer, thereby optimizing assembly space and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional electric motor with transmission is used in the actuator, then the required actuating power can be generated, but the assembly space requirement increases significantly
Solution Approach 1:
The Vernier motor integrates the motor stator, rotor, and transmission components into a single compact unit. The transmission is positioned within the motor housing, merging previously separate components into one integrated assembly that delivers the same actuating power in a significantly reduced volume
Solution Approach 2:
The transmission components are nested within the motor housing structure. The planetary gear set and other transmission elements are arranged concentrically and axially within the available space of the motor assembly, allowing compact packaging while maintaining full functional capability
2Force
If a conventional electric motor is used, then sufficient torque is available, but the weight of the actuator increases
Solution Approach 1:
The Vernier motor employs a high pole count design with numerous small magnets arranged in a specific pattern, changing the magnetic field parameters to achieve high torque density. This allows the motor to generate the required torque with significantly less material and lower overall weight compared to conventional motor designs
3Reliability
If conventional electric motors are used, then reliable power transmission is achieved, but the use of rare-earth materials increases
Solution Approach 1:
The Vernier motor design uses a high number of poles with smaller individual magnets, changing the magnetic circuit parameters to achieve the same or better performance with reduced rare-earth material content. The optimized magnetic flux distribution maintains reliability while reducing material consumption
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 configuration results in a more compact, lightweight, and energy-efficient roll stabilizer that minimizes vehicle rolling and provides a smoother driving experience by reducing assembly space requirements and lowering energy consumption, while also reducing the need for rare-earth materials.
Implementation Method 1
an electric motor which is designed as a Vernier motor and is connected, as a drive, to the transmission
Data Source
AI summary
A roll stabilizer for a motor vehicle having a housing (137, 237) with a first stabilizer element (110, 210) coupled to the housing and an electric motor (150, 250) located in the housing (137, 237). The transmission (160, 260) is coupled to the electric motor (150, 250) on a drive side, and the output side of the transmission (160, 260) is coupled to a second stabilizer element (115, 215) such that the stabilizer elements are electromechanically rotatable with respect to one another. The electric motor is designed as a Vernier motor.