Patent Application
20250132621
The present disclosure is directed to a method of forming a multi-component rotating assembly from two or more components, such as a rotor carrier and a bearing carrier of an electric motor, that is adapted to carry or transmit a torque or load, and to such a rotating assembly.
Multi-component rotating assemblies formed of two or more components are generally known. Some assemblies may consist of two carrier plates that are connected together in a torque transmitting manner. Assembling the carrier plates together can be accomplished by various means, such as separate fasteners, an interference fit, or welding.
These known techniques for achieving the connection between carrier plates have certain drawbacks. For example, interference fits require precise dimensional control, and can result in radial deformation and high stresses in sensitive areas of a rotating or spinning assembly. Separate fasteners, such as rivets or bolts, require additional assembly steps as well as drilling or otherwise forming aligned holes for the fasteners. Welding can result in deformation of parts as well as localized areas of the parts having the material properties that are negatively affected. Additionally for rotating assemblies, each of these methods involves different requirements for further balancing of the rotating assembly as well as alignment between the parts.
Accordingly, it would be desirable to provide an improved method of forming a rotating assembly.
A method of forming rotating assembly, the method includes a) providing a first rotating part and a second rotating part, the first rotating part having a first body with a radially extending outer rim portion, and the second rotating part having a receiving area defined by a radially extending inner flange with an inwardly extending shoulder defined thereon, b) forming a plurality of anti-rotation encapsulation recesses in the first body at least one of at or adjacent to the radially extending outer rim portion, c) placing the first rotating part into the second rotating part with the radially extending outer rim portion of the first rotating part adjacent to the radially extending inner flange of the second rotating part, with a portion of the first rotating body being axially supported by the inwardly extending shoulder, and d) staking respective portions of the second rotating part into respective ones of the plurality of anti-rotation encapsulation recesses via application of an axial load to form staking elements such that the staking elements enable the transmission of torque between the first and second rotating parts.
The first rotating part can be placed into the second rotating part with the radially extending outer rim portion of the first rotating part adjacent to the radially extending inner flange of the second rotating part with a clearance fit or a location fit.
In another aspect, a rotating assembly, which may be part of an electric motor for an electric or hybrid-electric vehicle drivetrain, is provided and includes a first rotating part, which can be formed of cast metal, having a first body with a radially extending outer rim portion, a second rotating part, which can be formed as stamped or deep-drawn thin walled metal, having a receiving area defined by a radially extending inner flange with an inwardly extending shoulder defined thereon, and a plurality of anti-rotation encapsulation recesses located in the first body at least one of at or adjacent to the radially extending outer rim portion. The first rotating part is located in the second rotating part with the radially extending outer rim portion of the first rotating part adjacent to the radially extending inner flange of the second rotating part, and a portion of the first rotating body is axially supported by the inwardly extending shoulder. Staking elements of the second rotating part that are formed via the application of an axial load extend into respective ones of the plurality of anti-rotation encapsulation recesses such that the staking elements enable the transmission of torque between the first and second rotating parts.
The first rotating part can be located in the second rotating part with a clearance fit or a locational fit.
Additional embodiments are disclosed herein.
The foregoing Summary and the following Detailed Description will be better understood when read in conjunction with the appended drawings, which illustrate a preferred embodiment of the disclosure. In the drawings:
Certain terminology is used in the following description for convenience only and is not limiting. The words “front,” “rear,” “upper” and “lower” designate directions in the drawings to which reference is made. The words “inwardly” and “outwardly” refer to directions toward and away from the parts referenced in the drawings. “Axially” refers to a direction along the axis of a shaft. A reference to a list of items that are cited as “at least one of a, b, or c” (where a, b, and c represent the items being listed) means any single one of the items a, b, or c, or combinations thereof. The terms “about” and “generally” mean within 10% of a specified value. The terminology includes the words specifically noted above, derivatives thereof and words of similar import.
A “thin-walled” stamped or drawn metal part as used herein generally has a wall thickness in the range of 0.2 mm-5.0 mm.
Referring now to
In order to join the first rotating part 20 with the second rotating part 30 in a torque-transmitting manner, a plurality of anti-rotation encapsulation recesses 40 are located in the first body 22 of the first rotating part 20 that at least one of at or adjacent to the radially extending outer rim portion 24. In the illustrated embodiment, there are a plurality of the anti-rotation encapsulation recesses 40 that are equally spaced apart in a radial direction. For example, there may be eight anti-rotation encapsulation recesses 40 that are spaced apart by 45° in a circumferential direction. However, the specific number of the anti-rotation encapsulation recesses 40 can be varied depending on the torque to be transmitted, but is at least two. Further, the anti-rotation encapsulation recesses 40 may be pocket-shaped, as shown in detail in
As shown in detail in
Referring now to
As shown in detail in
As shown in
In one arrangement, the radially inner face 54 extends generally parallel to the axis A of the rotating assembly 10. Further, the radially outer face 56 extends at an angle θ with respect to the axis A which is for example between 3° and 60°, as indicated in
Further, the staking elements 50 each include a radially extending portion 60 that extends over at least a portion of an axial end surface of the radially extending outer rim portion 24 of the first rotating part 20. This holds the first rotating part 20 axially in position in the second rotating part 30 with the radially extending outer rim portion 24 clamped between the inwardly extending shoulder 36 and the radially extending portions 60 of the staking elements 50.
As shown in
As shown in
This arrangement of the rotating assembly 10 can be used for example in an electric motor 12 as shown in
Referring now to
As indicated at 102, the method further includes forming a plurality of anti-rotation encapsulation recesses 40 in the first body 22 at least one of at or adjacent to the radially extending outer rim portion 24. As indicated at 104, the method further includes placing the first rotating part 20 into the second rotating part 30 with the radially extending outer rim portion 24 of the first rotating part 20 adjacent to the radially extending inner flange 34 of the second rotating part 30, with a portion 26 of the first rotating part 20 being axially supported by the inwardly extending shoulder 36. As indicated at 106, the method further includes staking respective portions of the second rotating part 30 into respective ones of the plurality of anti-rotation encapsulation recesses 40 via application of an axial load F to form staking elements 50 such that the staking elements 50 enable the transmission of torque between the first and second rotating parts 20, 30.
The method may further include the components of the rotating assembly 10 including one or more of the features described above.
Using this method, the rotating assembly 10 can be assembled without the precise tolerances required for an interference fit as well as avoiding any resulting radial deformation in sensitive areas of a thin-walled part in a rotating or spinning assembly. Further, fasteners such as rivets or bolts as well as welding can be avoided. By adjusting the number and size of the anti-rotation encapsulation recesses 40 and staking elements 50, the amount of torque that can be transmitted is also adjusted based on a particular application.
Having thus described the present embodiments in detail, it is to be appreciated and will be apparent to those skilled in the art that many physical changes, only a few of which are exemplified in the detailed description of the disclosure, could be made without altering the inventive concepts and principles embodied therein.
It is also to be appreciated that numerous embodiments incorporating only part of the preferred embodiment are possible which do not alter, with respect to those parts, the inventive concepts and principles embodied therein.
The present embodiment and optional configurations are therefore to be considered in all respects as exemplary and/or illustrative and not restrictive, the scope of the disclosure being indicated by the appended claims rather than by the foregoing description, and all alternate embodiments and changes to this embodiment which come within the meaning and range of equivalency of said claims are therefore to be embraced therein.
This application claims the benefit of U.S. Provisional Application No. 63/591,774, filed Oct. 20, 2023, which is incorporated herein by reference as if fully set forth.
| Number | Date | Country | |
|---|---|---|---|
| 63591774 | Oct 2023 | US |
