Abstract: Present disclosure discloses a stator mount (20) of an electric machine of a vehicle (100). The stator mount (20) includes a base (20A) defined with a first major surface (21 A) and a second major surface (21B). The base is connectable to an inner surface (11) of a crankcase cover (10), where the first major surface of the base is adapted to abut with the inner surface of the crankcase cover when connected. Further, the stator mount includes at least one elastic member (40) interposed between the first major surface (21 A) of the base (20A) and a mounting surface (12) of the inner surface (11) of the crankcase cover (10). The at least one elastic member (40) assists in attenuating noise and vibration emanating from the electric machine and mitigates the transmission of noise and vibration to the crankcase cover.
Present disclosure generally relates to vehicles. Particularly, but not exclusively, the present disclosure relates to an electric machine of vehicles. Further, embodiments of the present disclosure disclose a stator mount for securing a stator of the electric machine in a crankcase of an engine of the vehicles.
BACKGROUND OF THE DISCLOSURE
[002] The information in this section merely provides background information related to the present disclosure and may not constitute prior art(s) for the present disclosure.
[003] Vehicles conventionally include an internal combustion engine or an electric motor or a combination of both [hybrid], which serves as a power unit for generating power required for driving the vehicle. Engine based vehicles typically include a four-stroke engine which may have one or more cylinders depending on the power requirements. The single or multiple cylinders in the engine are associated with a crankshaft which delivers power to wheels of the vehicle through a transmission unit. The crankshaft is usually enclosed in a housing called crankcase. The crankcase serves several purposes such as serving as an oil sump or reservoir to store oil used for lubrication, resulting in a "wet sump" engine arrangement. Apart from being an oil reservoir, the crankcase encloses the crankshaft and may take part in supporting and housing several components associated with the crankshaft or other components of the engine. For example, the crankcase may support number of bearings including main bearing of the crankshaft, and the crankcase may be defined with a number of walls, ribs, pockets, oil passages, etc., for structural purposes. Besides the bearings, the crankcase also takes part in supporting various dynamic components directly or indirectly, for example, the flywheel of the engine, the oil pump intended to deliver lubricating oil to various engine components, electric machines such as alternating current generator (ACG)/alternator, an integrated starter generator (ISG) and so on.
[004] Presence of these components in the crankcase leads to crankcase being subjected to various dynamic loads and effects of noise and vibrations. For instance, an electric machine such as an ACG or an ISG housed in the crankcase would be subjected to dynamic effects like torsional vibrations and noise due to inherent torque fluctuations. The vibrations give rise to whistling noise which may cause discomfort to the users of the vehicle. Resonance may occur which is likely to increase torsional vibration amplitude that needs to be attenuated/diffused
appropriately for mitigating the effects of noise as well as to improve the durability of the crankcase structure. The extent of noise and vibration is also sometimes amplified by direct metal to metal contact between the dynamic components and the inner profile of the crankcase. Efforts like enhancing the overall rigidity of crankcase so as to impart high vibration and noise diffusion characteristics to the crankcase have been made in the past. However, there is need for a satisfactory solution to effectively address the problems of vibration, noise and compromised torsional characteristics such as torsional rigidity/stiffness of the crankcase and crankcase components.
[005] Present disclosure is directed to overcome one or more limitations stated above or other such limitations associated with the existing arts.
SUMMARY OF THE DISCLOSURE
[006] One or more shortcomings of conventional crankcase are overcome, and additional advantages are provided through the electric machine and the stator mount as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered as a part of the claimed disclosure.
[007] In one non-limiting embodiment of the disclosure, a stator mount of an electric machine of a vehicle is disclosed. The stator mount includes a base defined with a first major surface and a second major surface. The base is connectable to an inner surface of a crankcase cover. Further, at least one elastic member is interposed between the first major surface of the base and the inner surface of the crankcase cover. The at least one elastic member assists in attenuating noise and vibrations emanating from the electric machine and mitigates the transmission of noise and vibration to the crankcase cover.
[008] In an embodiment of the disclosure, where the first major surface of the base is adapted to abut with the inner surface of the crankcase cover when connected.
[009] In an embodiment of the disclosure, the base is defined with a flange portion extending from the second major surface of the base, where the flange portion is adapted to secure a stator of the electric machine. The flange portion improves structural rigidity and mounting characteristics when the stator of the electric machine is connected to the stator mount, thereby ensuring a sturdy connection of the electric machine relative to the crankcase.
[0010] In an embodiment of the disclosure, at least one of the first major surface of the base and the inner surface of the crankcase cover is defined with one or more grooves, each of the one or more grooves configured to accommodate the at least one elastic member. The one or more grooves may ensure precise positioning of the at least one elastic member to optimize the attenuation of noise and vibration, as well as to mitigate transmission of noise and vibration to the crankcase cover due to direct contact between the stator mount and the crankcase cover.
[0011] In an embodiment of the disclosure, the electric machine is one of electric generator, an integrated starter generator, and an electric motor.
[0012] In an embodiment of the disclosure, the inner surface of the crankcase cover is defined with a mounting surface complementing a profile of the first major surface of the base of the stator mount. This ensures proper positioning and alignment of the stator mount with the mounting surface which is beneficial in optimizing space consumption as well as to optimize distribution of loads and vibrations.
[0013] In an embodiment of the disclosure, one of the mounting surface and the first major surface is defined with a plurality of slots, each slot adapted to receive a crest defined on remaining of the first major surface and the mounting surface to sandwich the at least one elastic member between the first major surface and the inner surface of the crankcase cover. The crests received in the slots ensure that the stator mount is held and positioned accurately with respect to the mounting surface so that the at least one elastic member maintains even contact with both the mounting surface and the first major surface.
[0014] In an embodiment of the disclosure, each of the stator mount, the crankcase cover, and the stator is defined with one or more aligned apertures configured to receive a fastening member to secure the stator with the crankcase cover through the stator mount.
[0015] In an embodiment of the disclosure, the mounting surface is defined with one or more first apertures, each structured to align with a corresponding aperture defined in the base of the stator mount. The one or more first apertures aligning with the corresponding apertures defined in the base are adapted to receive first fastening elements to secure the stator mount with the mounting surface.
[0016] In an embodiment of the disclosure, the flange portion of the stator mount comprises one or more provisions, each provision including a second aperture structured to align with a corresponding aperture defined in the stator. Further, each second aperture aligned with the corresponding aperture defined in the stator is adapted to receive a second fastening element to secure the stator with the flange portion.
[0017] In an embodiment of the disclosure, the elastic member is a damper made of a material selected from at least one of polymers, metals and alloys.
[0018] In an embodiment of the disclosure, the inner surface of the crankcase cover is defined with a plurality of ribs, each extending between the mounting surface and a periphery of the crankcase cover. The plurality of ribs may improve torsional stiffness and rigidity of the crankcase cover by dissipation of torsional loads towards the periphery of the crankcase cover.
[0019] In another non-limiting embodiment of the disclosure, an electric machine associated with an engine of a vehicle is disclosed. The electric machine includes a stator connectable to a crankcase cover of the engine through a stator mount. The stator mount includes a base defined with a first major surface and a second major surface. The base is connectable to an inner surface of a crankcase cover, where the first major surface of the base is adapted to abut with the inner surface of the crankcase cover when connected. Further, at least one elastic member is interposed between the first major surface of the base and the inner surface of the crankcase cover. The at least one elastic member assists in attenuating noise and vibration emanating from the electric machine and mitigates the transmission of noise and vibration to the crankcase cover. Further, the electric machine includes a rotor configured to be coupled with a crankshaft of the engine, where the rotor is configured to rotate relative to the stator. The stator mount, apart from providing an improved mounting arrangement to secure the stator of the electric machine with the crankcase cover, it also ensures that the transmission of noise and vibration to the crankcase cover from the electric machine is minimized or controlled.
[0020] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined together to form further embodiments of the disclosure.
[0021] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further
aspects, embodiments, and features will become apparent by reference to the drawings and the
following detailed description.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWINGS
[0022] The novel features and characteristics of the disclosure are set forth in the description. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following description of an illustrative embodiment when read in conjunction with the accompanying drawings. One or more embodiments of the present invention are now described, by way of example only, with reference to the accompanied drawings wherein like reference numerals represent like elements and in which:
[0023] FIG. 1 illustrates a side view of a portion of a two wheeled vehicle showing some of the engine components, in accordance with an embodiment of the present disclosure;
[0024] FIG. 2 illustrates an exploded perspective view of a crankcase cover to which a stator is secured through a stator mount, in accordance with some embodiments of the present disclosure;
[0025] FIG. 3 illustrates a front view of the crankcase cover shown in FIG. 2 without the stator and the stator mount;
[0026] FIG. 4 illustrates perspective view of the stator mount of FIG. 2 showing a second major surface of the stator mount;
[0027] FIG. 5 illustrates perspective view of the stator mount of FIG. 2 showing a first major surface of the stator mount;
[0028] FIG. 6 illustrates a front view of the crankcase cover shown in FIG. 2 with the stator secured to the crankcase cover through the stator mount; and
[0029] FIG. 7 illustrates a sectional side view of the crankcase cover considered along section A-A in FIG. 6.
[0030] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the vehicle or the crankcase or the stator mount or the electric machine
illustrated herein may be employed without departing from the principles of the disclosure described herein. The drawings referred to in this description are not to be understood as being drawn to scale except if specifically noted, and such drawings are only exemplary in nature.
DETAILED DESCRIPTION
[0031] While the invention is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents, and alternative falling within the spirit and the scope of the invention.
[0032] Before describing detailed embodiments, it may be observed that the novelty and inventive step that are in accordance with the present disclosure resides in the configuration of a stator mount which is intended to secure a stator of an electric machine with a crankcase cover. It is to be noted that a person skilled in the art would be motivated from the present disclosure and modify the various constructions of the stator mount and the electric machine described thereof. However, such modifications should be construed within the scope of the present disclosure. Accordingly, the drawings are showing only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.
[0033] It is to be noted that a person skilled in the art would be motivated from the present disclosure and modify various features of the electric machine, without departing from the scope of the disclosure. Therefore, such modifications are considered to be part of the disclosure. Accordingly, the drawings show only those specific details that are pertinent to understand the embodiments of the present disclosure, so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skilled in the art having benefit of the description herein.
[0034] In the present disclosure, the term "exemplary" is used herein to mean "serving as an example, instance, or illustration". Any embodiment or implementation of the present subject
matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
[0035] The terms "comprises", "comprising", or any other variations thereof used in the disclosure, are intended to cover non-exclusive inclusions, such that a device or a system that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such a device or a system. In other words, one or more elements in the device or the system proceeded by "comprises... a" does not, without more constraints, preclude the existence of other elements or additional elements in the device or the system.
[0036] The terms like "at least one" and "one or more" may be used interchangeably or in combination throughout the description.
[0037] While the present disclosure is illustrated in the context of a two-wheeled vehicle, however, crankcase, electric machine and aspects and features thereof can be used with other type of vehicles as well. The terms "vehicle", "two-wheeled vehicle", and "motorcycle" have been interchangeably used throughout the description. The term "vehicle" comprises vehicles such as motorcycles, scooters, bicycles, mopeds, scooter type vehicle, all-terrain vehicles (ATV), and the like.
[0038] The terms "front/forward", "rear/rearward/back/backward", "up/upper/top/upward", "down/lower/lower ward/downward, bottom", "left/leftward", "right/rightward" used therein represents the directions as seen from a vehicle driver sitting astride.
[0039] For better understanding of the disclosure, reference would now be made to the embodiments illustrated in the accompanying figures and description here below. Further, in the following figures, the same reference numerals are used to identify the same components in various views.
[0040] Embodiments of the present disclosure disclose an electric machine associated with an engine of a vehicle. The electric machine includes a stator having a stator mount which includes a base defined with a first major surface and a second major surface. The base is connectable to an inner surface of a crankcase cover, where the first major surface of the base is adapted to abut with the inner surface of the crankcase cover when connected. Further, at least one elastic member is interposed between the first major surface of the base and the inner surface of the
crankcase cover. In an embodiment of the disclosure, the base is defined with a flange portion extending from the second major surface of the base, where the flange portion is adapted to secure the stator of the electric machine. Further, the electric machine may include a rotor disposed in the crankcase and coupled to the crankshaft such that the rotor is configured to rotate relative to the stator for generating electrical energy.
[0041] The following paragraphs describe the present disclosure with reference to FIGS. 1 to 7. In the figures, the same element or elements which have similar functions are indicated by the same reference signs.
[00035] FIG. 1 illustrates a side view of a portion of a vehicle (100) in accordance with some embodiments of the present disclosure. The vehicle (100) referred to herein, embodies a motorcycle or a motor bike. Alternatively, the vehicle (100) may embody any other ridden vehicles such as motorized scooter vehicle, all-terrain vehicles (ATV) etc., without limiting the scope of the disclosure. The vehicle (100) as shown depicts a few components like a portion of an internal combustion engine (50) and associated engine components, such as a crankcase (60), along with some sections of the frame (150) of the vehicle (100). The crankcase (60) may be concealed by a crankcase cover (10) which may be secured through outer fastening elements (10F) which will be described later.
[00036] The vehicle (100) may include, among other components, a front ground engaging member (114) and a rear ground engaging member (112). The front ground engaging member (114) may be operatively connected to a steering mechanism (110) having a handlebar (115). The handlebar (115) may be to be rotated by the rider to steer the vehicle (100). Further, the frame (150) may include various interconnected members and linkages. For instance, the frame (150) may have a frontal frame portion which may support the steering mechanism (110) having the handlebar (118) through a head tube or head pipe (80). A frontal member (153) extending from the head tube (80) may be in the form of a hollow rod or a pipe or a beam. Further, the frame (150) may include an upper frame portion and a lower frame portion connected to and extending from the head tube (80) [directly or indirectly]. A pair of side rails [not shown] extends upwardly and rearwardly from the lower frame portion and support the left seat rail and right seat rail [not shown], respectively. The left seat rail and right seat rail may in turn support the seat (160) of the vehicle (100). The frame (150) may include many other linkages and members which may take part in supporting several components, including the engine (50), the crankcase (60) and so on which are not discussed in detail. The frame (150)
may also support the transmission casing (200) which may enclose chain drives and sprockets associated with transmission of drive power to the rear ground engaging member (112). The engine (50) may be coupled to a transmission unit (70), like a gear box which allows variable transmission to the rear ground engaging member (112).
[00037] The handlebar may also be associated with a dash assembly (not shown). The dash assembly may include a display unit (not shown). The display unit may display information about the vehicle (100) to the rider. The dash assembly may comprise additional components including, but not limited to, LCD, GPS, and Graphical User Interface (GUI), switches etc. without limiting the scope of the invention. Further, the front-end structure of the vehicle (100) may further comprise additional components such as mirrors, head lamps, front fenders, light and horn switches, engine switches, ignition key provision, etc. without limiting the scope of the invention. Apart from these, the vehicle may also include, among other components, a seat arrangement, a taillight (170), suspension elements like cushions (175), swing arm, rear grip (180), electronic connections, and hydraulic connections, all of which are not illustrated for simplicity. The electronic connections may embody a wire harness. The hydraulic connections may embody fluid hoses. The rear end structure of the vehicle (100) may comprise additional components such as rear fender, rear lamp, license plate etc. without limiting the scope of the invention.
[00038] Embodiments of the present disclosure elucidate the configuration of the crankcase (60) which encloses a crankshaft [not shown] of the engine (50). The crankcase (60) may have a crankcase cover (10) connectable to one or either side of the crankcase (60) to conceal openings at the extremities. The crankcase cover (10) according to embodiments of the present disclosure may be intended to support one or more components associated with an electric machine, for example, an AC generator, an integrated starter generator or an electric motor, among other purposes. The crankcase cover (10) may be secured to the crankcase (60) by means of outer fastening elements (10F) received in the outer apertures (10R) [see FIGS. 3 and 6].
[0039] FIG. 2 is an exemplary embodiment of the present disclosure illustrating exploded perspective view of the crankcase cover (10) to which a stator mount (20) and a stator (30) of an electric machine [not shown] may be secured. Reference is also made to FIG. 3 which illustrates a front view of an interior of the crankcase cover (10) shown in FIG. 2. The crankcase cover (10), as shown, has a shell-like structure which may be manufactured by processes,
including but not limited to casting. The crankcase cover (10) may be assembled to the engine (50) system to conceal the crankcase (60) along with some portions of the engine (50) from sides. In an embodiment, two crankcase covers - left crankcase cover and right crankcase cover may be used to conceal left and right openings, respectively, of the crankcase (60). When assembled, an inner surface (11) of the crankcase cover (10) together with a periphery (10P) and an extended portion (10E) may enclose one or more components associated with the engine (50). In an embodiment, the crankcase cover (10) may enclose or house electric machines such as an alternating current generator (hereafter abbreviated as ACG), an integrated starter generator (hereafter abbreviated as ISG), a simple electric motor (hereafter abbreviated as EM) such as a starter motor and so on. Besides the electric machines, the crankcase cover (10) may also enclose or at least partially enclose some bearings, rotating parts, electrical parts and so on. In an embodiment, the crankcase (60) and the crankcase cover (10) may be manufactured from materials selected from metals, alloys and so on.
[0040] The crankcase cover (10), as shown in FIG. 2 and 3, may have an inner surface (11) which may constitute a majority of surface area of the crankcase cover (10). The flip side of the inner surface (11), i.e., the outer surface of the crankcase cover (10) may be seen in FIG. 1. The inner surface (11) may be circumscribed by the periphery (10P) and the extended portion (10E) to form the shell-like structure. The depth of the periphery (10P) measured from the inner surface (11) may vary from engine to engine and from vehicle to vehicle. As shown in FIG. 2, the crankcase cover (10) may accommodate the stator mount (20) which connects or secures the stator (30) of an electric machine, examples of which are provided above. The stator mount (20) [best shown in FIGS. 4 and 5] may include a base (20A) which may further be defined with a first major surface (21A) and a second major surface (21B). The first major surface (21 A) and the second major surface (21B) are defined on flip sides of the base (20A). The base (20A) may be in the form of a flanged block which may seat or abut with the inner surface (11) of the crankcase cover (10) to support the stator (30). To establish connection with the crankcase cover (10), the inner surface (11) of the crankcase cover (10) may be defined with a mounting surface (12) which may complement a profile of the first major surface (21 A) of the base (20A). In an embodiment, the mounting surface (12) [best shown in FIG. 3] may be defined integrally with the inner surface (11) of the crankcase cover (10), and may be imparted with surface features through surface machining/finishing operations. The stator mount (20) is connected to the mounting surface (12) such that the first major surface (21 A) of the base (20A) may abut or contact with the mounting surface (12) when connected.
[0041] Reference is now made to FIGS. 4 and 5 which illustrate the second major surface (2 IB) and the first major surface (21 A) respecitvely of the stator mount (20) shown in FIG. 2. FIGS. 2 and 3 are also referred in conjunction with FIGS. 4 and 5. The first major surface (21 A) of the stator mount (20), as shown in FIG. 5, may be defined with one or more crests (27) which may conform to a profile of one or more slots (14) defined in the mounting surface (12) of the crankcase cover (10) depicted in FIGS. 2 and 3. In an alternate embodiment, the features of crests (27) and the slots (14) may be interchanged, i.e., the mounting surface (12) may be defined with one or more crests (27) and the first major surface (21 A) of the base (20A) may be defined with one or more slots (14) which conform to the profile of the crests (27) present in the mounting surface (12). The crests (27) defined in any of the mounting surface (12) and the first major surface (21 A) may be received in the slots (14) defined in any one of the counter/corresponding/associated first major surface (21 A) and the mounting surface (12).
[0042] In an embodiment of the disclosure, crests (27) received in the slots (14) may allow at least one elastic member (40) be interposed or sandwiched between the first major surface (21 A) of the base (20 A) and the mounting surface (12) of the crankcase cover (10), as evident from FIG. 2. When the stator mount (20) is assembled or connected to the mounting surface (12), the first major surface (21A) may press the at least one elastic member (40) against the mounting surface (12). In alternate terms, the at least one elastic member (40) may be pressingly disposed between the mounting surface (12) and the first major surface (21 A) so as to manifest as an elastic interface between the mounting surface (12) and the first major surface (21 A). Such a positioning of the elastic member (40) facilitates damping of vibrations emanating from the electric machine transmitted via the stator (30) when assembled. The elastic member (40) may also inhibit transmission of vibrations, noise, and other loads to the crankcase cover (10) due to its inherent damping characteristics. In an embodiment, the elastic member (40) may also attenuate noise and undesirable sounds, such as, but not limited to a tingling or a whistling noise which may arise from contact or interaction between the stator mount (20) and the mounting surface (12) of the crankcase cover (10). For example, the elastic member (40) may attenuate noise and undesirable sounds emanating due to metal-to-metal interaction between the stator mount (20) and the crankcase cover (10), the metal-to-metal interaction arising by virtue of rotation of rotating parts in the electric machine.
[0043] In yet another embodiment, the geometrical features and material properties of the elastic material (40) may be such that it may eliminate or diminish a resonance condition which
may arise due to torsional vibrations emanating from the rotating elements of the electric machine. In still another embodiment, the elastic member (40) may reduce the extent of load transfer [dynamic loads] from the stator mount (20) to the crankcase cover (10) via the mounting surface (12). Further, in an exemplary configuration as shown in FIG. 5, an inner periphery (IP) and an outer periphery (OP) may define radial gaps relative to the crests (27) so that one or more ring shaped elastic members (40) may be disposed within the radial gaps. In one embodiment, the radial gaps may be in the form of grooves (G) or cut-outs or stepped slots which may accommodate a partial depth of the elastic members (40), so that the remaining depth of the elastic members (40) may project outside from the plane of the crests (27). The remaining depth projecting outside the plane of the crests (27) may undergo elastic deformation, for example, compression when the stator mount (20) is pressed and connected to the mounting surface (12). These characteristics of the elastic members (40) may take part in absorption/dissipation and/or damping of undesired loads, vibrations, shocks, and noises. In an embodiment, profile of grooves (G) or cut-outs or stepped slots may conform to the profile of the elastic member (40) to ensure firm seating of the elastic member (40) within.
[0044] In another embodiment, the mounting surface (12) may be defined with grooves (G) or cut-outs or stepped slots instead of the first major surface (21 A) of the stator mount (20), so that the elastic members (40) may reside [at least partially] in the grooves (G) or cut-outs or stepped slots of the mounting surface (12). This configuration again ensures that the elastic members (40) abut with both the mounting surface (12) and the first major surface (21 A) when sandwiched. In yet another embodiment, both the mounting surface (12) and the first major surface (21A) may be defined with the grooves (G) or cut-outs or stepped slots. This ensures that the elastic members (40) reside partially in grooves (G) or cut-outs or stepped slots of both the mounting surface (12) and the first major surface (21 A). In an embodiment of the disclosure, the elastic members (40) may have ring like structure with a circular, crescent, elliptical, U-shaped, C-shaped, V-shaped, oblong or other cross sections. In another embodiment, each elastic member (40) may be an O-ring, a gasket, or a seal with damping properties. In yet another embodiment, the elastic member (40) may be manufactured using materials selected from any one or more of elastomeric materials and viscoelastic materials, such as, but not limited to, natural rubber, synthetic rubber, nitrile rubber, silicone, urethane rubbers, chloroprene, Ethylene Vinyl Acetate (EVA rubber), or elastic natured metallic and other class of polymeric materials.
[0045] Referring back to FIG. 4, the second major surface (2IB) of the base (20A) may be defined with a flange portion (22) which projects from the second major surface (2IB). The flange portion (22) is structured to secure the stator (30) of the electric machine, as evident from FIG. 2. A central bore (28) may be defined in the flange portion (22) which may extend for the entire depth of the stator mount (20). The flange portion (22) may also have one or more provisions (23), each provision (23) having a second aperture (24), as shown in FIG. 4. In an embodiment, the provisions (23) may be in the form of rounded or U-shaped protrusions or extensions which may be defined integrally with the flange portion (22). Each provision (23) may be formed such that the second aperture (24) may be concentrically defined within the corresponding provision (23). In an exemplary embodiment as shown in FIG. 4, the number of provisions (23) may be three which are angularly spaced apart by 120 degrees [measured from center which results in an included angle of 60 degrees]. In another embodiment, the number of provisions (23) and the corresponding second apertures (24) may be less than three or more than three depending on requirement. Each of the second aperture (24) is structured to align with a corresponding aperture (31) defined in the stator (30) [see FIG. 2]. In an embodiment, the second aperture (24) aligning with the corresponding aperture (31) in the stator (30) may also align with apertures [not shown] in the mounting surface (12) to form aligned or through apertures. The aligned or through apertures may receive fastening elements (35) such that the stator (30) may be fastened to the mounting surface (12) of the crankcase cover (10) through the stator mount (20). In another embodiment of the disclosure, each of the stator mount (20), the crankcase cover (10), and the stator (30) may be defined with one or more aligned, through apertures [not shown] at locations different than the locations of the second apertures (24) and corresponding apertures (31) shown in FIG. 2. The aligned or through apertures may receive fastening elements (35) such that the stator (30) may be fastened and secured to the mounting surface (12) of the crankcase cover (10) through the stator mount (20).
[0042] In an embodiment of the disclosure, the stator (30) may be discretely connected to the mounting surface (12) of the crankcase cover (10) through two different aperture configurations. For instance, as shown in FIGS. 2 and 3, the mounting surface (12) may be defined with one or more first apertures (13), each structured to align with a corresponding aperture (25) defined in the base (20A) of the stator mount (20) shown in FIGS. 2, 4 and 5. In an embodiment as illustrated in FIGS. 4 and 5, rounded or U-shaped protrusions/extensions (29) may be formed integrally with the base (20A) during manufacturing of the stator mount (20). Each of these protrusion/extensions (29) may be formed such that the first aperture (25)
may be concentrically defined within the corresponding protrusion/extension (29). In an exemplary embodiment as shown in FIGS. 4 and 5, the number of protrusions/extensions (29) may be three which are angularly spaced apart by 120 degrees [measured from center which results in an included angle of 60 degrees]. In another embodiment, the number of protrusions/extensions (29) and the corresponding first apertures (25) may be less than three or more than three depending on requirement, for example, size and shape of the base (20A).
[0043] The one or more first apertures (13) aligning with the corresponding apertures (25) defined in the base (20A) are adapted to receive first fastening elements (26) to secure the stator mount (20) with the mounting surface (12) of the crankcase cover (10). This completes the connection between the stator mount (20) and the crankcase cover (10). Now, the flange portion (22) having one or more provisions (23), and therefore, the second apertures (24), may align with the corresponding apertures (31) defined in the stator (30) [see FIG. 2]. The aligned second apertures (24) and the corresponding apertures (31) in the stator (30) may receive the second fastening elements (32), so that the stator (30) may be fastened and secured to the flange portion (22) of the stator mount (20). Through the above-described discrete set of connections, the stator (30) may be secured to the mounting surface (12). The discrete connections allow the stator (30) to be dismantled from the stator mount (20) without having to detach the stator mount (20) from the crankcase cover (10). In an embodiment of the disclosure, the inner surface (11) of the crankcase cover (10) may be defined with a plurality of ribs (15), each extending between the mounting surface (12) and the periphery (10P) of the crankcase cover (10). The plurality of ribs (15) may improve torsional stiffness and rigidity of the crankcase cover (10), by dissipation of torsional loads towards the periphery (10P) of the crankcase cover (10). In an embodiment, the plurality of ribs (15) may extend radially and may improve other mechanical properties of the crankcase cover (10). In an embodiment as apparent from FIGS. 3 and 6, a plurality of auxiliary ribs (16) and surface features (17) may be defined on the inner surface (11). The auxiliary ribs (16) may be defined on the inner surface (11) such that they may be viewed from a bore (MA) in the mounting surface (12). The auxiliary ribs (16), like the ribs (15) may also take part in improving torsional stiffness of the stator mount () . The bore (MA) may align and conform to dimensions of the stator hub bore (SA) and the central bore (28) of the stator mount (20). The surface features (17) may include, among other features, some ribs, pockets, stiffeners, ridges, crests and valleys which may take part in load and vibration distribution and/or transmission, and improvement of mechanical/structural characteristics.
[0044] Reference is now made to FIGS. 6 and 7 to illustrate an exemplary electric machine connected to the crankcase cover (10). FIG. 6 illustrates a front view of the crankcase cover (10) with the stator (30) of the electric machine secured to the mounting surface (12) through the stator mount (20). FIG. 7 illustrates a sectional side view of the crankcase cover (10) and stator (30) assembly of FIG. 6 considered along section A-A. The electric machine, which may be an ACG, an ISG or an EM as described in the previous paragraphs is intended either to generate electrical output by providing a mechanical input [like an ACG], or generate mechanical output by giving an electrical input [like an EM], or a hybrid combination of both [like an ISG]. The electric machine in accordance with embodiments of the present disclosure may include the stator (30) as shown in FIGS. 2 and 6, and a rotor (not shown). The stator (30) remains stationary while the rotor may be rotated by means of external mechanical power [like in case of ACG] or by means of electro-magnetic interaction [like in case of EM]. The stator (30) may have a hub (H) and a plurality of poles (AR). The hub (H) may be seated on the flange portion (22), so that the stator (30) may be supported on the mounting surface (12) through the stator mount (20), with the elastic members (40) disposed/sandwiched therebetween [FIG. 2]. The poles (AR) may be distributed circumferentially about the hub (H) as shown. The poles (AR) may be composed of coil windings, while the rotor may have magnetic armatures [the configuration may be reversed where stator may have stationary magnetic poles while the rotor can be armatures having coils]. With the rotor remaining stationary before start, if the coil windings [in the stator or the rotor] are energized with electric current, the electro-magnetic interaction [changing magnetic flux or electric flux linking with the counterparts] sets the rotor in rotation[mechanical output]. This is the scenario for an EM. When the effect is reversed, i.e., if the rotor is given a mechanical input to set it in rotation, the fluctuation in magnetic interaction with the coils due to rotation of the rotor generates electricity in the rotor. This is the scenario for an ACG. A hybrid combination of both results in an ISG, where in one instance the ISG operates as an EM, particularly as starter motor for the engine (50), and in other instance the ISG operates as an ACG to generate AC. The first and second fastening elements (32/35, 26) may be clearly seen in FIGS. 6 and 7. In an embodiment, the fastening elements may include, but not limited to bolts and rivets, while the first apertures, second apertures and corresponding apertures may be threaded or unthreaded holes.
[0046] The stator mount (20) of the present disclosure may provide several advantages.
[0047] One advantage is that the at least one elastic member (40) assists in attenuating noise and vibrations emanating from the electric machine and mitigates the transmission of noise and vibration to the crankcase cover (10). This improves the durability of the crankcase and prevents discomfort to the passengers due to inherent noise.
[0048] Another advantage is that the flange portion of the stator mount may improve mountability of the stator of the electric machine on the stator mount, thereby ensuring a sturdy connection of the electric machine relative to the crankcase. This is beneficial in mitigating unwanted noise and vibrations, as well as loads which may arise if the connections are not proper or if there are misalignments.
[0049] A still another advantage is that the one or more grooves provided to receive the elastic members ensure precise positioning of the elastic members to optimize the attenuation of noise and vibration, as well as to mitigate transmission of noise and vibration to the crankcase cover due to direct contact between the stator mount and the crankcase cover.
[0050] While few embodiments of the present disclosure have been described above, it is to be understood that the invention is not limited to the above embodiments and modifications may be appropriately made thereto within the scope of the invention.
[0051] Herein, the terms "attached", "connected", "interconnected", "contacting", "mounted", "coupled" and the like can mean either direct or indirect attachment or contact between elements, unless stated otherwise.
[0052] While considerable emphasis has been placed herein on the particular features of this invention, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other modifications in the nature of the invention or the preferred embodiments will be apparent to those skilled in the art from the invention herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
[0053] Herein, the terms "attached", "connected", "interconnected", "contacting", "mounted", "coupled" and the like can mean either direct or indirect attachment or contact between elements, unless stated otherwise
[0054] It is to be understood that a person of ordinary skill in the art may develop a vehicle or an electric machine or a crankcase or a stator mount of similar configuration without deviating from the scope of the present disclosure. Such modifications and variations may be made without departing from the scope of the present disclosure. Therefore, it is intended that the present disclosure covers such modifications and variations provided they come within the ambit of the appended claims and their equivalents.
[0055] Well-known functions or constructions may not be described in detail for brevity and/or clarity. As used herein the expression "and/or" includes any and all combinations of one or more of the associated listed items.
Equivalents:
[0056] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
[0057] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an
introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to "at least one of A, B, and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B, and C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances, where a convention analogous to "at least one of A, B, or C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system (100) having at least one of A, B, or C" would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase "A or B" will be understood to include the possibilities of "A" or "B" or "A and B." While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope being indicated by the following claims.
claim:
1. A stator mount (20) of an electric machine of a vehicle (100), the stator mount (20)
comprising:
a base (20A) defined with a first major surface (21 A) and a second major surface (21B), the base (20A) connectable to an inner surface (11) of a crankcase cover (10); and
at least one elastic member (40) interposed between the first major surface (21 A) of the base (20A) and the inner surface (11) of the crankcase cover (10).
2. The stator mount (20) as claimed in claim 1, wherein the first major surface (21A) of the base (20 A) adapted to abut with the inner surface (11) of the crankcase cover (10) when connected.
3. The stator mount (20) as claimed in claim 1, wherein the base (20A) is defined with a flange portion (22) extending from the second major surface (21B) of the base (20A), the flange portion (22) adapted to secure a stator (30) of the electric machine.
4. The stator mount (20) as claimed in claim 1, wherein at least one of the first major surface (21 A) of the base (20A) and the inner surface (11) of the crankcase cover (10) is defined with one or more grooves (G), the one or more grooves (G) configured to accommodate the at least one elastic member (40).
5. The stator mount (20) as claimed in claim 1, wherein the electric machine is one of electric generator, an integrated starter generator, and an electric motor.
6. The stator mount (20) as claimed in claim 1, wherein the inner surface (11) of the crankcase cover (10) is defined with a mounting surface (12) complementing a profile of the first major surface (21 A) of the base (20 A) of the stator mount (20).
7. The stator mount (20) as claimed in claims 1 and 5, wherein one of the mounting surface (12) and the first major surface (21 A) defined with a plurality of slots (14), each slot (14) adapted to receive a crest (27) defined on remaining of the first major surface (21 A) and the mounting surface (12) to sandwich the at least one elastic member (40) between the first major surface (21 A) and the inner surface (11) of the crankcase cover (10).
8. The stator mount (20) as claimed in claim 1, wherein each of the stator mount (20), the crankcase cover (10), and the stator (30) is defined with one or more aligned apertures configured to receive a fastening member (35) to secure the stator (30) with the crankcase cover (10) through the stator mount (20).
9. The stator mount (20) as claimed in claim 5, wherein the mounting surface (12) is defined with one or more first apertures (13), each structured to align with a corresponding aperture (25) defined in the base (20A) of the stator mount (20), and wherein the one or more first apertures (13) aligning with the corresponding apertures (25) defined in the base (20A) are adapted to receive first fastening elements (26) to secure the stator mount (20) with the mounting surface (12).
10. The stator mount (20) as claimed in claim 1, wherein the flange portion (22) of the stator mount (20) comprises one or more provisions (23), each provision (23) including a second aperture (24) structured to align with a corresponding aperture (31) defined in the stator (30),
wherein each second aperture (24) aligning with the corresponding aperture (31) defined in the stator (30) is adapted to receive a second fastening element (32) to secure the stator (30) with the flange portion (22).
10. The stator mount (20) as claimed in claim 1, wherein the at least one elastic member (40) is a damper made of a material selected from at least one of polymers, metals and alloys.
11. The stator mount (20) as claimed in claims 1 and 5, wherein the inner surface (11) of the crankcase cover (10) is defined with a plurality of ribs (15), each extending between the mounting surface (12) and a periphery (10P) of the crankcase cover (10).
12. An electric machine associated with an engine (50) of a vehicle (100), the electric machine comprising:
a stator (30) connectable to a crankcase cover (10) of the engine (50) through a stator mount (20), the stator mount (20) comprising:
a base (20A) defined with a first major surface (21 A) and a second major surface (21B), the base (20A) connectable to an inner surface (11) of the crankcase cover (10), wherein the first major surface (21 A) of the base (20A)
adapted to abut with the inner surface (11) of the crankcase cover (10) when
connected, and
at least one elastic member (40) interposed between the first major
surface (21 A) of the base (20A) and the inner surface (11) of the crankcase
cover (10), and
a rotor configured to be coupled with a crankshaft of the engine (50), wherein the rotor is configured to rotate relative to the stator (30).
13. The electric machine as claimed in claim 12, wherein a mounting surface (12) is defined with one or more first apertures (13) structured to align with corresponding apertures (25) defined in the base (20A), the one or more first apertures (13) aligning with the corresponding apertures (25) are adapted to receive first fastening elements (26) to secure the stator mount (20) with the mounting surface (12).
14. The electric machine as claimed in claim 12, wherein the base (20A) is defined with a flange portion (22) extending from the second major surface (21B) of the base (20A), the flange portion (22) adapted to secure the stator (30) of the electric machine.
15. The electric machine as claimed in claim 12, wherein at least one of the first major surface (21 A) of the base (20A) and the inner surface (11) of the crankcase cover (10) is defined with one or more grooves (G), each of the one or more grooves (G) configured to accommodate the at least one elastic member (40).
| # | Name | Date |
|---|---|---|
| 1 | 202211007311-STATEMENT OF UNDERTAKING (FORM 3) [11-02-2022(online)].pdf | 2022-02-11 |
| 2 | 202211007311-POWER OF AUTHORITY [11-02-2022(online)].pdf | 2022-02-11 |
| 3 | 202211007311-FORM 1 [11-02-2022(online)].pdf | 2022-02-11 |
| 4 | 202211007311-DRAWINGS [11-02-2022(online)].pdf | 2022-02-11 |
| 5 | 202211007311-DECLARATION OF INVENTORSHIP (FORM 5) [11-02-2022(online)].pdf | 2022-02-11 |
| 6 | 202211007311-COMPLETE SPECIFICATION [11-02-2022(online)].pdf | 2022-02-11 |
| 7 | 202211007311-Proof of Right [21-06-2022(online)].pdf | 2022-06-21 |
| 8 | 202211007311-FORM 18 [09-04-2024(online)].pdf | 2024-04-09 |