WO2022017647A1

WO2022017647A1 - Stator-armature assemblies with edges disposed at angles

Info

Publication number: WO2022017647A1
Application number: PCT/EP2021/025279
Authority: WO
Inventors: Pratik Agarwal; Ashish Kumar; Rupesh SURVE
Original assignee: Eaton Intelligent Power Limited
Priority date: 2020-07-23
Filing date: 2021-07-23
Publication date: 2022-01-27

Abstract

A differential system includes a power source, a differential assembly component, a stator and an armature. The stator includes a first section and a second section that are substantially parallel to each other and adhered to respective ends of a third section that is substantially perpendicular to the first and second sections. The first and second sections include two respective subsections that form angles relative to an axis of the differential assembly component, the plurality of sections forming a cavity in which an electromagnetic coil is disposed. The armature includes a plurality of additional sections including fillets.

Description

STATOR-ARMATURE ASSEMBLIES WITH EDGES DISPOSED AT ANGLES

FIELD OF THE INVENTION

[0001] The instant application is directed to stator and armature assemblies including edges that are parallel to one another and disposed at angles relative to a differential axis.

BACKGROUND OF THE INVENTION

[0002] Differentials are mechanical devices used to facilitate the transmission of power from driveshafts to the wheels of vehicles, thereby enabling vehicle rotation. Differentials may include stators and armatures that operate in conjunction with each other. The automotive industry faces a rising demand for differentials having compact designs for accommodation within machines (e.g., vehicles) with various space constraints.

[0003] Manufacturing differentials to have compact designs, however, requires reducing the dimensions of various components, e.g., the stator, the armature, and a preloaded spring. However, reducing the dimensions of the stator and preloaded spring beyond certain threshold values may result in the generation of a stator force that is less than a force generated by the preloaded spring, which in turn, adversely impacts the operation of the differentials. Additionally, geometries and other properties of the components of differentials limit the extent to which the dimensions of these components may be reduced.

[0004] Accordingly, there is a need for a differential system that includes a stator-armature assembly that may be designed to comply with certain compact design requirements while simultaneously ensuring that a force generated by the stator is increased or maintained at a level that ensures effective operation of the stator-armature assembly.

SUMMARY OF THE INVENTION

[0005] In one aspect, there is disclosed a differential system comprising a power source, a differential assembly component, a stator, and an armature. The stator includes a first section and a second section that are substantially parallel to each other and adhered to respective ends of a third section that is substantially perpendicular to the first and second sections. The first and second sections include two respective subsections that form angles relative to an axis of the differential assembly component, the plurality of sections forming a cavity in which an electromagnetic coil is disposed. The armature includes a plurality of additional sections including fillets.

[0006] In another aspect, a stator-armature assembly comprising a stator and an armature. The stator including a plurality of sections, the plurality of sections including a first section and a second section that are substantially parallel to each other and adhered to respective ends of a third section that is substantially perpendicular to the first section and the second section. The first section and the second section including two respective subsections that form angles relative to an axis of a differential assembly component that is external to the stator-armature assembly. The plurality of sections forming a cavity in which an electromagnetic coil is disposed. The armature including a plurality of additional sections that form a curved recess for receiving a portion of the stator, a subset of the plurality of additional sections including fillets.

[0007] Additional features and advantages of the differential system described herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments described herein, including the detailed description which follows, the claims, as well as the appended drawings.

[0008] It is to be understood that both the foregoing general description and the following detailed description describe various embodiments and are intended to provide an overview or framework for understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding of the various embodiments, and are incorporated into and constitute a part of this specification. The drawings illustrate the various embodiments described herein and together with the description serve to explain the principles and operations of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0010] FIG. 1 depicts an example of a conventional design of a stator-armature assembly;

[0011] FIG. 2 depicts a stator-armature assembly that includes a stator having a plurality of sections such that these sections form a cavity in which an electromagnetic coil is disposed;

[0012] FIG. 3 A depicts an expanded graphical representation of the stator-armature assembly of FIG. 2, according to one or more embodiments described and illustrated herein; [0013] FIG. 3B depicts an isolated view of a subsection of a second section of the stator- armature assembly depicted in FIG. 3A, according to one or more embodiments described and illustrated herein;

[0014] FIG. 3C depicts an isolated view of a subsection of a first section of the stator- armature assembly depicted in FIG. 3A, according to one or more embodiments described and illustrated herein;

[0015] FIG. 3D depicts an isolated view of an armature depicted in FIG. 3A, according to one or more embodiments described and illustrated herein;

[0016] FIG. 3E depicts an isolated view of a fourth edge of a subsection directly interfacing with or contacting a portion on an interior of a section of an armature, according to one or more embodiments described and illustrated herein;

[0017] FIG. 3F depicts an isolated view of a fourth edge of a subsection directly interfacing with or contacting a portion on an interior of a section of an armature, according to one or more embodiments described and illustrated herein; [0018] FIG. 4 depicts another isolated view of a design of the armature that includes a plurality of fillets, according to one or more embodiments described and illustrated herein;

[0019] FIG. 5 depicts a graphical representation of an magnetic flux generated by an example stator-armature assembly, according to one or more embodiments described and illustrated herein; [0020] FIG. 6 depicts a graphical representation of the stator-armature assembly installed as part of an example differential system, according to one or more embodiments described and illustrated herein; and

[0021] FIG. 7 depicts a graphical representation of locking forces generated by the example stator-armature assembly as depicted in FIG. 1 as compared to the stator-armature assembly of the present disclosure as depicted in FIG. 2, according to one or more embodiments described and illustrated herein.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] In one aspect, a differential system described herein includes a stator-armature assembly that may be designed to comply with certain compact design requirements while simultaneously ensuring that a force generated by the stator is increased or maintained at a level that ensures effective operation of the stator-armature assembly. However, prior to describing the operation of the differential system described herein, a description of the deficiencies of current designs of differentials is instructive. [0023] FIG. 1 depicts an example of a conventional design of a stator-armature assembly. As illustrated, the conventional design of the stator-armature assembly includes an armature 100 that is designed to receive an example stator 104. The example armature 100 may be manufactured as a machine component and include a recess for receiving the example stator 104. The example stator 104 may be designed such that an example electromagnetic coil 102 may be disposed within or adhered to an interior portion of the example stator 104. The example electromagnetic coil 102 is a component that generates a certain amount of electronic magnetic flux that serves as a locking force for locking or linking the example stator 104 to the example armature 100. The locking force that is generated may be adjusted based on adjusting a value of the diameter of a portion of the example armature 100, namely a diameter value of an example inside leg 106 that has a curved shape and is designed to contact an exterior portion of the example stator 104. It is noted that the diameter value of the example inside leg 106 is utilized to calculate the magnetic flux that serves as the locking force for locking the example stator 104 to the example armature 100.

[0024] In operation, when the example armature 100 of the stator-armature assembly depicted in FIG. 1 is in motion, the radial component of the magnetic flux that is generated by the stator-armature assembly causes a reduction in an axial force that acts on the example armature 100. This reduction adversely impacts the operation of the stator-armature assembly, which in turn, negatively impacts the operation of the differential system in which the stator-armature assembly is included, e.g., a differential system that includes the stator-armature assembly operating in conjunction with a power source, a locking plate, and a differential component, as illustrated in FIG. 6.

[0025] It is noted that, as stated above, any reductions in the dimensions of the example stator 104 beyond a certain threshold may result in a force generated by the example stator 104 that is less than the force generated by a preloaded spring, which results in an ineffective operation of the stator-armature assembly depicted in FIG. 1. Additionally, as stated above, the shape and geometry of the example stator 104 and example armature 100 may limit any additional reductions in dimensions of these components. [0026] The stator-armature assembly of the present disclosure addresses and overcomes these deficiencies. Specifically, FIG. 2 depicts a stator-armature assembly that includes a stator 200 having a plurality of sections such that these sections form a cavity in which an electromagnetic coil 202 is disposed. Additionally, the stator 200 may be positioned in association with or adhered to an armature 204. The armature 204 includes a plurality of sections (additional sections) that form a curved recess for receiving a portion of the stator 200. In embodiments, the armature 204 may include a plurality of fillets. [0027] FIG. 3 A depicts an expanded graphical representation of the stator-armature assembly of FIG. 2, according to one or more embodiments described and illustrated herein. Specifically, FIG. 3A depicts a stator 200 including a plurality of sections, namely a first section 302, a second section 304, and a third section 300. The first and second sections 302, 304 are substantially parallel to each other and are attached or adhered to two ends (e.g., respective ends) of a third section 300. As illustrated in FIG. 3A, the third section 300 is substantially perpendicular to the first and second sections 302, 304.

[0028] Additionally, the first and second sections 302, 304 include two respective subsections 308, 306 that are disposed at angles relative to an axis 307. The subsection 308 is the bottom portion of the first section 302 and is positioned to contact or interface with a portion on the interior of the armature 204. Similarly, the subsection 306 is the bottom portion of the second section 304 and is positioned to contact or interface with another portion on the interior of the armature 204. It is noted that the manner in which the subsections interface with the interior portions of the armature 204, in part, address and overcome the deficiencies of the conventional design of the stator-armature assembly depicted in FIG. 1 and described above. [0029] FIG. 3B depicts an isolated view of the subsection 306 of the second section 304 of the stator-armature assembly depicted in FIG. 3A, according to one or more embodiments described and illustrated herein. As illustrated, the subsection 306 includes a plurality of edges, a subset of which directly interface with or contact interior portions of the armature 204. The subsection 306 (a first subsection) includes a first edge 310 and a second edge 312 that are substantially parallel to each other. Moreover, these edges are parallel to the axis 307 depicted in FIG. 3 A, which may correspond to an axis of a differential component (not shown) that is external to the stator-armature assembly.

[0030] The subsection 306 also includes a third edge 314 that is substantially perpendicular to the first and second edges 310, 312, and the axis 307. In embodiments, a ratio of a length of the third edge 314 relative to a thickness of the third edge 314 is in a range of 0.3 to 0.7. Additionally, the subsection 306 includes a fourth edge 316 that is disposed at an angle relative to the axis 307. The angle at which the fourth edge 316 may be disposed may range from twenty degrees relative to the axis 307 to fifty degrees relative to the axis 307. In operation, when the stator 200 is positioned on or in association with the armature 204, the edges 312, 314 and 316 directly interface or contact multiple portions on the interior of the armature 204.

[0031] FIG. 3C depicts an isolated view of the subsection 308 of the first section 302 of the stator-armature assembly depicted in FIG. 3 A, according to one or more embodiments described and illustrated herein. As illustrated, the subsection 308 of the first subsection 302 includes a plurality of edges, a subset of which directly interface with or contact interior portions of the armature 204. Specifically, the subsection 308 (a second subsection) includes a first edge 320 that is parallel to the axis 307, a second edge 322 that is perpendicular to the axis 307, and a third edge 324 that is disposed at an angle relative to the axis 307. The angle at which the third edge 324 may be disposed may range from twenty degrees relative to the axis 307 to fifty degrees relative to the axis 307. Additionally, it is noted that a ratio a length of the second edge 322 relative to a thickness of the second edge 322 is in a range of 0.3 to 0.7. [0032] FIG. 3D depicts an isolated view of the armature 204 depicted in FIG. 3 A, according to one or more embodiments described and illustrated herein. Specifically, FIG. 3D depicts each section of a plurality of sections included as part of the armature 204, namely sections 330, 332, 334, 336, and 338. As illustrated, section 332 may be disposed at an angle ranging from twenty degrees relative to the axis 307 to fifty degrees relative to the axis 307, and as such, may be adhered to or joined with sections 330 and 334. Additionally, as illustrated, section 336 may also be disposed at an angle ranging from twenty degrees relative to the axis 307 to fifty degrees relative to the axis 307, and as such, may be adhered to or joined with sections 338 and 334. It is noted that the design of sections 332 and 336 in additional to the disposition of these sections at an angle enables for the reduction of air reluctance, which in turn facilitates effective operation of the stator-armature assembly.

[0033] It is further noted that electromagnetic flux density depends on an orientation of a surface. Specifically, a surface that is perpendicular to the axis 307 generates a higher electromagnetic flux value relative to a surface that is parallel to the axis 307. As such, the electromagnetic flux corresponding to the section 334 may be higher than the electromagnetic flux corresponding to the section 336. The electromagnetic flux corresponding to the section 336 may be higher than the flux corresponding to section 332. The electromagnetic flux corresponding to section 332 may be larger than the electromagnetic flux corresponding to section 338. The electromagnetic flux corresponding to section 338 may be larger than the electromagnetic flux corresponding to section 330.

[0034] FIG. 3E depicts an isolated view of the fourth edge 316 of the subsection 306 directly interfacing with or contacting a portion on the interior of the section 336 of the armature 204. Specifically, as illustrated, the fourth edge 316 may come in direct contact with an edge of the section 336 (e.g., a corresponding portion) that is disposed at the angle (e.g., an angle that is the same as the angle) at which the fourth edge 316 is disposed. In other words, if the fourth edge 316 is disposed at an angle of twenty degrees relative to the axis 307, the edge of the section 336 may also be disposed at a comparable angle. It is noted that the angle at which the fourth edge 316 is disposed may range from twenty degrees relative to the axis 307 to fifty degrees relative to the axis 307.

[0035] FIG. 3F depicts an isolated view of the third edge 324 of the subsection 308 directly interfacing with or contacting a portion on the interior of the section 332 of the armature 204. Specifically, as illustrated, the third edge 324 may come in direct contact with an edge of the section 332 (e.g., a corresponding portion) that is disposed at an angle (e.g., an additional angle that is the same as the angle) at which the third edge 324 is disposed. In other words, if the third edge 324 is disposed at an angle of fifty degrees relative to the axis 307, the edge of the section 336 may also be disposed at a comparable angle. It is noted that the angle at which the third edge 324 is disposed may range from twenty degrees relative to the axis 307 to fifty degrees relative to the axis 307.

[0036] FIG. 4 depicts another isolated view of a design of the armature 204 that includes a plurality of fillets, according to one or more embodiments described and illustrated herein. Specifically, FIG. 4 depicts the armature 204 that includes the sections 330, 332, 334, 336, and 338, in additional to fillets 404 (e.g., a first fillet) and 406 (e.g., a second fillet). The fillet 404, as positioned, is configured to join section 330 with section 332 and fillet 406, as position, is configured to join section 332 with section 334. It is noted that a fillet refers to manufacturing or designing a particular component to include a rounded or curved portion on an interior or exterior portion of the component. In embodiments, the fillet 404 may have a radius ranging from two millimeters to five millimeters. Similarly, the fillet 406 may also have a radius ranging from two millimeters to five millimeters.

[0037] FIG. 5 depicts a graphical representation of an magnetic flux generated by an example stator-armature assembly, which includes an example stator 500 that is positioned in association with an example armature 502, according to one or more embodiments described and illustrated herein. The electromagnetic flux, which is generated by the stator-armature assembly and indicated by directions 504, 508, may be utilized to calculate a locking force 506 that may be utilized to link or associate the stator 500 to the armature 502. The locking force 506 may be determined based the following algorithms:

[0038] It is noted that the locking force, denoted by F_x, may be increased by adjusting the diameter “D” of the armature 502.

[0039] FIG. 6 depicts a graphical representation of the stator-armature assembly installed as part of an example differential system, according to one or more embodiments described and illustrated herein. Specifically, FIG. 6 depicts an example differential system that includes a power source 600 that is coupled to the armature 204 via a rod or beam structure. The armature 204 is coupled to the stator 200 in which an electromagnetic coil is disposed. Additionally, the example differential system includes a locking plate 602 coupled to a metal component that is utilized to link the differential assembly component 604 to the armature 204. It is noted that, in operation, as the armature 204 move towards the stator 200, the spring force generated by an preloaded spring installed in association with the stator-armature assembly increases.

[0040] FIG. 7 depicts a graphical representation of locking forces generated by the example stator-armature assembly as depicted in FIG. 1 as compared to the stator-armature assembly of the present disclosure as depicted in FIG. 2, according to one or more embodiments described and illustrated herein. Specifically, as illustrated, the graphical representation of FIG. 7 depicts locking forces illustrated as a function of air gaps.

[0041] An x-axis 700 of the graphical representation of FIG. 7 corresponds to air gaps that are measured in millimeters and a y-axis 702 that corresponds to force measured in Newtons. A curve 704 corresponds to the locking force profile of the example stator-armature assembly depicted in FIG. 1 and a curve 706 corresponds to the locking profile of the stator-armature assembly depicted of the present disclosure, as depicted in FIG. 2. As shown, toward the top of the two curves, the curve 706 has a higher locking force as compared to the locking force generated by the conventional design of a stator-armature assembly illustrated in FIG. 1. Table 1, shown below, lists various locking force measurements of the conventional stator-armature assembly design and the stator-armature assembly of the present disclosure at various air gap levels and corresponding to an electromagnetic coil excitation level of 285 amperes:

TABLE 1

[0042] Additionally, tables 1 and 2, shown below, depict various parameters of components of each of the conventional stator-armature assembly depicted in FIG. 1 and the stator-armature assembly of the present disclosure, as depicted in FIGS. 2 and 3.

TABLE 2

TABLE 3

[0043] As indicated in the tables above, in embodiments, the locking force of the stator- armature assembly of the present disclosure is determined to be 49.8506551, while the locking force of the conventional design based stator-armature assembly as illustrated in FIG. 1 is determined to a lower value of 47.26804182. [0044] In this way, the stator-armature assembly is designed to comply with certain compact design requirements while simultaneously ensuring that a force generated by the stator is increased or maintained at a level that ensures effective operation of the stator-armature assembly. It is noted that the stator-armature assembly of the present disclosure has numerous advantages over conventional stator-armature assembly designs.

[0045] In particular, the stator-armature assembly of the current disclosure enables the generation of stator force that exceeds any frictional force between the stator 200 and the armature 204. Additionally, in embodiments, the armature 204 may be generated via multi-step manufacturing process (e.g., a stamping process) that provides the armature 204 with sharp edges and a smooth finish on the surface of the armature. Consequently, the likelihood that the armature 204 will experience magnetic saturation is reduced.

Claims

1. A differential system comprising: a power source; a differential assembly component; a stator including a plurality of sections, the plurality of sections including a first section and a second section that are substantially parallel to each other and adhered to respective ends of a third section that is substantially perpendicular to the first section and the second section, the first section and the second section including two respective subsections that form angles relative to an axis of the differential assembly component, the plurality of sections forming a cavity in which an electromagnetic coil is disposed; and an armature including a plurality of additional sections that form a curved recess for receiving a portion of the stator, a subset of the plurality of additional sections including fillets.

2. The differential system of claim 1, wherein the two respective subsections include a first subsection that forms an angle ranging from twenty degrees relative to the axis to fifty degrees relative to the axis.

3. The differential system of claim 2, wherein the two respective subsections include a second subsection that forms an additional angle ranging from twenty degrees relative to the axis to fifty degrees relative to the axis.

4. The differential system of claim 1, wherein the subset of the plurality of additional sections including the fillets includes a first fillet having a radius ranging from two millimeters to five millimeters.

5. The differential system of claim 1, wherein the subset of the plurality of additional sections including the fillets includes a second fillet having a radius ranging from 0.2 millimeters to five millimeters.

6. The differential system of claim 1, wherein the two respective subsections of the first section include: a first subsection including a plurality of edges, the plurality of edges including: a first edge and a second edge that are substantially parallel to each other and to the axis, a third edge that is substantially perpendicular to the first edge, the second edge, and the axis, and a fourth edge that is disposed at an angle relative to the axis.

7. The differential system of claim 6, wherein a ratio of a length of the third edge relative to a thickness of the third edge is in a range of .3 to .7.

8. The differential system of claim 6, wherein the fourth edge is parallel to a corresponding portion of one of the plurality of additional sections of the armature, the corresponding portion is disposed at the angle at which the fourth edge is disposed.

9. The differential system of claim 1, wherein the two respective subsections of the second section include: a second subsection including a plurality of edges, the plurality of edges including: a first edge that is parallel to the axis and a second edge that is perpendicular to the axis, a ratio of a length of the second edge relative to a thickness of the second edge is in a range of 0.3 to 0.7, and a third edge that is disposed at an angle relative to the axis.

10. The differential system of claim 9, wherein the third edge is parallel to a corresponding portion of one of the plurality of additional sections of the armature, the corresponding portion is disposed at the angle at which the third edge is disposed.

11. A stator-armature assembly comprising: a stator including a plurality of sections, the plurality of sections including a first section and a second section that are substantially parallel to each other and adhered to respective ends of a third section that is substantially perpendicular to the first section and the second section, the first section and the second section including two respective subsections that form angles relative to an axis of a differential assembly component that is external to the stator- armature assembly, the plurality of sections forming a cavity in which an electromagnetic coil is disposed; and an armature including a plurality of additional sections that form a curved recess for receiving a portion of the stator, a subset of the plurality of additional sections including fillets.

12. The stator-armature assembly of claim 11, wherein the two respective subsections include a first subsection that forms an angle ranging from twenty degrees relative to the axis to fifty degrees relative to the axis.

13. The stator-armature assembly of claim 12, wherein the two respective subsections include a second subsection that forms an additional angle ranging from twenty degrees relative to the axis to fifty degrees relative to the axis.

14. The stator-armature assembly of claim 11, wherein the subset of the plurality of additional sections including the fillets includes a first fillet having a radius ranging from two millimeters to five millimeters.

15. The stator-armature assembly of claim 11, wherein the subset of the plurality of additional sections including the fillets includes a second fillet having a radius ranging from 0.2 millimeters to five millimeters.

16. The stator-armature assembly of claim 11, wherein the two respective subsections of the first section include: a first subsection including a plurality of edges, the plurality of edges including: a first edge and a second edge that are substantially parallel to each other and to the axis, and a third edge that is substantially perpendicular to the first edge, the second edge, and the axis.

17. The stator-armature assembly of claim 16, wherein the plurality of edges further including a fourth edge that is disposed at an angle relative to the axis.

18. The stator-armature assembly of claim 17, wherein a ratio of a length of the third edge relative to a thickness of the third edge is in a range of .3 to .7.

19. The stator-armature assembly of claim 11, wherein the two respective subsections of the second section include: a second subsection including a plurality of edges, the plurality of edges including: a first edge that is parallel to the axis and a second edge that is perpendicular to the axis, and a third edge that is disposed at an angle relative to the axis.

20. The stator-armature assembly of claim 19, wherein a ratio of a length of the second edge relative to a thickness of the second edge is in a range of .3 to .7.