Wheel Bearing Generator with Nested Stator and Rotor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The size of the stator and rotor in existing wheel bearing apparatuses limits the generation power due to the outer diameter of the inner member, restricting design freedom and installation space for the generator.
Innovation Solution
A wheel bearing apparatus with a generator where the stator is mounted on the inner-side of the body mounting flange of the outer member, and permanent magnets are positioned radially outward of a shoulder part of the outer joint member, allowing for increased magnetic field components and reduced generator size, enabling more efficient use of space and higher generation power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the generator is arranged in the engine compartment with conventional components, then the installation space is sufficient, but the space density becomes excessive and design freedom is reduced
Solution Approach 1:
The patent combines the generator with the wheel bearing apparatus by integrating the stator to the outer member and mounting the rotor on the inner member. This merging of functions allows the generator to be installed in the wheel hub area rather than requiring separate engine compartment space, thereby reducing space density while maintaining adequate installation area
Solution Approach 2:
The wheel bearing apparatus is designed to serve multiple functions: it provides bearing support for the wheel while simultaneously housing the generator components. The outer member serves both as a bearing component and as the stator mounting structure, while the inner member serves as both a bearing component and rotor mounting structure, thereby eliminating the need for separate generator installation space
2Power
If the generator size is increased to improve generation power, then the magnetic field components can be enhanced, but the installation space in the engine compartment becomes insufficient
Solution Approach 1:
The patent relocates the generator from the conventional engine compartment (two-dimensional plane) to the wheel hub area (three-dimensional space utilizing radial and axial dimensions). This dimensional change allows for larger magnetic field components and higher generation power without consuming additional engine compartment space, as the generator utilizes the radial space between the inner and outer members
3Volume of moving object
If the stator and rotor size are limited by the outer diameter of the inner member, then the generator size is reduced, but the generation power is limited
Solution Approach 1:
The generator components are nested within the wheel bearing structure: the rotor is mounted on the inner member and the stator is attached to the outer member, creating a nested configuration. This nesting allows the magnetic field components to utilize the available radial space efficiently, enabling larger generator size and higher generation power without exceeding the outer diameter constraint of the inner member
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 reduces the generator's size within the engine compartment, providing additional space and allowing for increased generation power, while maintaining bearing rigidity and durability through optimized rolling element arrangement and sealing.
Implementation Method 1
a stator forming part of a generator is mounted on an inner-side of a body mounting flange (2b) of the outer member (2), and permanent magnets (29) are mounted in a rotor case (31) formed radially outward of a shoulder (17) of an outer joint member (12) and arranged oppositely to the stator via an air gap
Data Source
Figure 1
Figure 2
Figure 3(a)~3(c)
AI summary
Provided is a wheel bearing apparatus with a generator which has a high degree of freedom of design, is able to keep a sufficient installation space for the generator, and is also able to increase the generation power due to size-up of magnetic field components. An axially extending annular projection (21) is formed on an inner-side surface (2c) of the body mounting flange (2b) of the outer member (2), a stator (23) forming the generator (30) is accommodated within an annular space (22) formed between the annular projection (21) and an outer circumferential surface (2d) of the outer member (2), and permanent magnets (29) are mounted in a flange-shaped rotor case (31) formed radially outward of a shoulder part (17) of the outer joint member (12) and arranged oppositely to the stator (23) via an axial air gap.