Wheel-Side Resolver Coupling for Precise Rotor Alignment
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Solution Overview
Problem
Existing wheel designs face challenges in achieving a compact and accessible design while ensuring precise detection of the angular position of the rotor, particularly when the resolver is separate from the electric motor, leading to potential misalignment due to play or tolerances.
Innovation Solution
A wheel side design with a resolver separate from the electric motor, using form-fitting elements to ensure a defined angular position between the resolver's rotary part and the rotor, eliminating the need for precise re-calibration during installation or maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the resolver is formed separately from the electric motor to improve accessibility and maintenance, then ease of repair is improved, but measurement precision deteriorates due to potential misalignment from play or tolerances
Solution Approach 1:
A form-fitting element acts as an intermediary component between the resolver's rotary part and the electric motor's rotor. This intermediary ensures precise angular positioning by mechanically coupling the two components without play, while allowing the resolver to remain separately mounted for ease of maintenance and replacement.
2Measurement precision
If the resolver is directly integrated into the electric motor to ensure precise angular position detection, then measurement precision is improved, but ease of repair deteriorates due to blocked access during maintenance
Solution Approach 1:
The form-fitting element serves as a mediator that enables precise angular positioning while maintaining physical separability. This allows the resolver to be mounted independently on the rotor, providing direct angular position detection without requiring the resolver to be integrated into the electric motor housing, thus preserving accessibility during maintenance.
3Ease of repair
If the resolver is indirectly connected via the drive shaft to improve accessibility, then ease of repair is improved, but reliability deteriorates due to potential play or tolerances in connecting elements
Solution Approach 1:
The form-fitting element acts as a reliable intermediary that directly couples the resolver's rotary part to the rotor, eliminating the need for indirect connection through the drive shaft. This direct coupling removes potential sources of error from play or tolerances in intermediate connecting elements, ensuring reliable angular position detection while maintaining accessibility.
Data Source
AI summary
A wheel side comprises: an electric motor that comprises a stator and a rotor; a drive shaft that is connected to the rotor for a common rotation about an input axis so that a drive power generated by the electric motor can be output to further components of the wheel side via the drive shaft; and a resolver for detecting the angular position of the rotor, wherein the resolver comprises a stationary part and a rotary part and the rotary part of the resolver is connected to the rotor of the electric motor for a common rotation about the input axis. In this respect, the resolver is formed separately from the electric motor. Provision is furthermore made that the wheel side has a form-fitting element that is arranged eccentrically with respect to the input axis and that engages in a form-fitting manner into a hole formed at the rotary part, on the one hand, and into a hole formed at the rotor, on the other hand, to ensure a defined angular position of the rotary part relative to the rotor.