Hybrid Belt Driven Starter Generator Electric Motor Shaft and Claw Poles Press Fit Simulation and Correlation with Physical Measurements

Belt-driven starter generator claw pole electric motors are used in hybrid automobiles to start the engine, charge the battery and to power the electrical system when its engine is running. Shaft and claw pole are important components in the claw pole electric motor. The claw pole is fitted onto the shaft through press-fit force. Press-fit is a widely used fastening process to join two different components by pushing a component inside or over another component with high press force which will create a strong bond between the components. Determining press-fit force required to assemble parts is very complex since it depends on a lot of factors such as mechanical material properties of components, interference fit condition whether it is in Min, mean and max condition, amount of contact pressure induced by contact surface, co-efficient of friction created in between components. The press-fit will help to prevent loosening components from its bond at high torque and speed. More over prediction of press-fit force is required to select pneumatic/hydraulic press machine capacity and to freeze the standard operating procedure in the assembly line. In this journal, the required shaft and claw poles press-fit force predicted to assemble for Min, mean and max fit condition by adopting contact non-linearity and material non-linearity technique in Finite element analysis (FEA) using Ansys Workbench and compared the FEA calculated results with theoretical calculation, physical measurements.