Wheel Motor with Integrated Controller for Compact Packaging
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Solution Overview
Problem
Existing electric wheel motors face packaging constraints and durability issues due to the large size of the motor and external control device placement, which affects their integration and performance in vehicles.
Innovation Solution
A compact wheel motor design featuring a stator with a U-shaped core made of insulated powdered metal, a rotor with aligned magnets, and integrated winding elements and controllers within the stator body, allowing for a three-dimensional magnetic flux generation and reduced external components, thereby improving packaging efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric wheel motors are used to replace gasoline engines, then fuel economy is improved and emissions are reduced, but packaging constraints arise due to large motor size
Solution Approach 1:
The patent transitions from conventional two-dimensional planar motor designs to a three-dimensional configuration where the stator core extends radially outward and winding elements are disposed circumferentially around the core. This dimensional change allows for more efficient space utilization and compact packaging while maintaining motor performance
Solution Approach 2:
The controller is integrated within a pocket formed in the stator body, creating a nested configuration where the controller is housed inside the motor assembly rather than being external. This nesting principle reduces overall packaging volume by eliminating separate mounting space for control electronics
2Ease of manufacture
If control devices are positioned external to the wheel motor assembly, then ease of manufacturing is improved, but durability issues arise
Solution Approach 1:
The controller and stator are merged into a single integrated assembly where the controller is positioned within a pocket in the stator body. This combination protects the controller from external environmental factors and mechanical damage while simplifying the overall assembly into one durable unit that rotates as a single entity
3Volume of moving object
If a compact wheel motor design is implemented with integrated components, then packaging constraints are reduced, but device complexity increases
Solution Approach 1:
The stator is divided into functional segments: a body portion containing the controller pocket, a radially extending core for magnetic flux, and radial slots for winding elements. This segmentation allows each component to be optimized independently while maintaining overall compactness and simplifying manufacturing of individual parts
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 design enables a more compact and reliable wheel motor assembly that reduces packaging constraints and durability issues, enhancing fuel efficiency and reducing emissions by integrating control components within the motor, thus improving vehicle performance.
Implementation Method 1
The controller can be coupled to the at least one winding element and can be arranged to selectively provide a supply of current to the at least one winding element to generate a magnetic flux to rotate the rotor relative to the stator
Implementation Method 2
The controller can be arranged to selectively provide a supply of current to the at least one winding element to generate a three dimensional magnetic flux to rotate the rotor relative to the stator
Data Source
AI summary
A wheel motor can include a stator adapted to be coupled to a vehicle. The stator can include a body portion and a core extending radially outward from the body portion. A rotor can be disposed about the stator and can have a portion positioned radially outboard of and around the stator core. The rotor can include a plurality of magnets aligned with the stator core, and can be adapted to be coupled to a rotatable vehicle component. At least one winding element can be disposed circumferentially around the stator core, and a controller can be positioned in a pocket integrally formed in the stator body portion. The controller can be coupled to the at least one winding element and can be arranged to selectively provide a current supply to the at least one winding element to generate a magnetic flux to rotate the rotor relative to the stator.