In-Wheel Motor Labyrinth Sealing for Moisture, Salt, and Mud
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Solution Overview
Problem
In-wheel motors for electric vehicles face challenges in protecting against foreign substances such as moisture, salt, and mud, especially in harsh environments and varying temperature conditions, which can lead to ingress and malfunction.
Innovation Solution
A sealing apparatus with a labyrinth structure and encased seal is integrated into the in-wheel motor, featuring rotating supports and a self-lubricating encased seal with diamond-like carbon coating, to prevent foreign substance ingress and maintain smooth operation across temperature extremes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a complex structure with mechanical, electrical, and electronic components is integrated in the in-wheel motor, then the motor achieves functional completeness and performance, but the vulnerability to foreign substance ingress increases due to more sealing interfaces and components
Solution Approach 1:
The patent implements a multi-layer nested sealing structure where the lip seal is positioned inside the hollow sealing member, creating concentric protective barriers. The lip seal's sealing lip contacts the rotating shaft while the hollow sealing member provides an additional protective chamber, forming a nested arrangement that protects against foreign substance ingress without compromising the integrated motor's functional completeness
Solution Approach 2:
The hollow sealing member acts as an intermediary protective element between the external environment and the internal motor components. It provides an additional barrier that intercepts foreign substances before they can reach the lip seal and motor components, mediating the protection against harmful factors while allowing the complex motor structure to function
2Reliability
If the in-wheel motor is designed for harsh environments with extreme temperatures and poor road conditions, then the operational reliability improves, but the sealing requirements become more stringent and complex
Solution Approach 1:
The lip seal utilizes a flexible sealing lip made of elastomeric material that can deform and adapt to the rotating shaft surface. This flexible membrane structure provides effective sealing against harsh environments including extreme temperatures and contaminants, while maintaining a relatively simple overall design compared to rigid multi-component sealing systems
Solution Approach 2:
The sealing system combines different materials with complementary properties: the lip seal uses elastomeric material for flexibility and sealing contact, while the hollow sealing member provides structural support and additional protection. This composite material approach enhances reliability in harsh environments without requiring overly complex structural designs
3Object-affected harmful factors
If a lip seal is used for sealing the rotating shaft, then the sealing effectiveness improves, but friction and wear between the sealing lip and shaft increase
Solution Approach 1:
The hollow sealing member is designed to rotate together with the shaft, creating a self-lubricating effect where the relative motion between the stationary hollow sealing member and rotating shaft generates lubrication that reduces friction and wear on the lip seal. The system serves itself by using the operational motion to reduce the harmful effects of friction
Solution Approach 2:
The hollow sealing member provides prior protection by intercepting foreign substances and reducing the severity of contact between the lip seal and shaft. It acts as a cushioning barrier that lessens the wear and friction effects before they fully impact the sealing components, extending their service life
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 sealing apparatus effectively blocks foreign substances and ensures smooth lubrication, enhancing the in-wheel motor's durability and performance in diverse environmental conditions, including extreme temperatures and harsh environments.
Implementation Method 1
with diamond-like carbon coating
Implementation Method 2
a grease G filled in an empty space between an inner surface of the case 643 and the diaphragm 644
Data Source
AI summary
An in-wheel motor for an electric vehicle is provided, including a motor body (1) including a wheel hub (11) on one side, and a sealing apparatus (2) mounted to the motor body (1) on the opposite side to the wheel hub (11), in which the sealing apparatus (2) includes a first support (510) fixedly coupled to a motor shaft (14) of the motor body (1), a second support (520) fixedly coupled to the motor shaft (14) and disposed outside the first support (520), a third support (530) covering an outer surface of the first support (510) and an outer circumferential surface of the second support (520), and rotated when the motor is operated, and a fourth support (540) coupled to an outer surface of the second support (520) and rotated when the motor is operated.