A low power high torque cable puller structure

Abstract

This invention discloses a low-power, high-torque tensioner structure, including a first housing and a drive component disposed within the first housing. The first housing also includes a drum and a reduction mechanism. The drum is used to wind a tension rope for use by external personnel. The drive component is connected to the drum via the reduction mechanism, which reduces the output speed of the drive component and amplifies the output torque. The structure also includes a tensioning mechanism. The reduction mechanism includes a pulley assembly and a transmission belt disposed on the pulley assembly. The transmission belt has wedge-shaped protrusions. The tensioning mechanism includes an elastic component and a stop component. The elastic component applies force to the stop component, causing the stop component to abut against the transmission belt, thereby applying tension to the transmission belt. This significantly improves transmission smoothness, reliability, and service life, allowing the overall structure to balance high torque output and long-term operational stability within a compact layout.

Description

Technical Field

[0001] This invention relates to the field of fitness equipment and mechanical transmission technology, and in particular to a low-power, high-torque resistance band structure. Background Technology

[0002] With the development of fitness equipment and small mechanical transmission devices, users have placed higher demands on the power output, structural compactness, and transmission stability of these devices. This is especially true in devices requiring high torque output, such as resistance bands, where a motor or other drive mechanism is typically used to rotate a drum to apply tension.

[0003] Currently, gearboxes and synchronous belts are used to achieve speed reduction in the market. However, resistance bands have very strict requirements for smoothness and automatic recovery force. Both of these methods have gaps and unevenness when the resistance rope is retracted, which cannot achieve the ideal performance. Therefore, the applicant thought of using multi-wedge belts for transmission. When using multi-wedge belts for transmission, the multi-wedge belts will fully engage with the transmission wheel, and the resistance rope will be relatively smooth when pulling outward and retracting. However, after testing, the applicant found that multi-wedge belts used in multi-stage transmissions will wear after a certain period of use, and the tension between the two transmission wheels will decrease, causing slippage. Since resistance bands require low speed and high torque, multi-wedge belts will also experience jamming and unevenness. Therefore, a low-power, high-torque, compact resistance band is proposed to solve the above problems. Even with wear, the multi-wedge belt can maintain a tight fit with the transmission wheel under the pressure of the rollers during long-term use, ensuring smooth pulling and retracting of the resistance band and greatly increasing the service life of the product. Summary of the Invention

[0004] To overcome the shortcomings of the prior art, the present invention provides a low-power, high-torque tensioner structure.

[0005] The technical solution adopted by this invention to solve its technical problem is: This invention provides a low-power, high-torque tensioner structure, including a first housing and a drive component disposed within the first housing. The first housing also includes a drum and a reduction mechanism. The drum is used to wind a tension rope for use by external personnel. The drive component is connected to the drum via the reduction mechanism. The reduction mechanism is used to reduce the output speed of the drive component and amplify the output torque. The invention also includes a tensioning mechanism. The reduction mechanism includes a pulley assembly and a transmission belt disposed on the pulley assembly. The transmission belt has wedge-shaped protrusions. The tensioning mechanism includes an elastic component and a stop component. The elastic component applies a force to the stop component, causing the stop component to abut against the transmission belt to apply tension to the transmission belt.

[0006] In this technical solution, the transmission belt is a wedge belt.

[0007] Preferably, the tensioning mechanism further includes a second housing disposed on the first housing. The second housing has a first groove for accommodating the elastic component and a second groove for limiting the movement path of the stop member. The second groove is strip-shaped, and its length direction is parallel to the movement direction of the stop member. By providing an installation position for the tensioning mechanism through the first groove for accommodating the elastic component and the strip-shaped second groove for limiting the movement path of the stop member on the second housing, the tensioning mechanism is ensured to move linearly along a predetermined direction. This achieves precise guidance and control of the direction of the elastic tension force, thereby improving the reliability and consistency of the tensioning action.

[0008] Preferably, the first housing is further provided with a rod body, the driving component is an external rotor motor mounted on the rod body, and the output end of the driving component is provided with a first wheel body; The reduction mechanism includes a first pulley rotatably disposed relative to the first housing. The diameter of the first pulley is larger than the diameter of the first wheel body. The transmission belt includes a first belt body. The first wheel body is connected to the first pulley via the first belt body. The stop member of the tensioning mechanism abuts against the first belt body. By setting the driving component as an external rotor motor on the rod body and setting the first wheel body at its output end, together with the larger diameter first pulley and the first belt body connecting the two, a first-stage reduction transmission is formed. The stop member of the tensioning mechanism abuts against the first belt body, and the tensioning ensures the high efficiency and stability of the first-stage belt transmission, thereby effectively increasing the system output torque and preventing slippage within a limited space.

[0009] Preferably, the drum is rotatably mounted on the rod, and a second wheel is provided on the outer periphery of the end of the drum near the drive member; The reduction mechanism also includes a second pulley, which is fixed relative to the first pulley. The transmission belt includes a second belt body, and the second pulley body is connected to the second pulley via the second belt body. The stop member of the tensioning mechanism abuts against the second belt body. By setting the second pulley body at one end of the drum and setting the second pulley fixed to the first pulley, the second belt body connects the second pulley body and the second pulley, forming a second-stage reduction transmission. The stop member also abuts against the second belt body, which plays the role of using the two-stage belt transmission to perform secondary reduction and further amplify the torque finally output to the drum. At the same time, the stop member synchronously tensions the two-stage transmission belts, realizing the simplification of the transmission system structure and the balanced distribution of the overall tension force, ensuring smooth and synchronous transmission between the two stages.

[0010] Preferably, both the first pulley and the second pulley are mounted on a pulley assembly. The pulley assembly includes a limiting member and a first shaft rotatably mounted on the limiting member. A second bearing is provided between the first shaft and the limiting member to support the rotation of the first shaft. The limiting member is fixedly mounted on the first housing. The first pulley and the second pulley are respectively located at both ends of the first shaft along its length. By setting up a pulley assembly including the limiting member, the first shaft, and the second bearing, and fixing the first pulley and the second pulley to both ends of the first shaft, the pulleys of the two-stage reduction gears are integrated into an independent module that can be installed as a whole. The limiting member is used to fix the pulleys to the first housing, and the second bearing supports the rotation of the first shaft. This achieves modular and high coaxiality installation of the reduction mechanism, improving assembly efficiency and transmission accuracy.

[0011] Preferably, the limiting member is annular, and the first shaft is rotatably disposed on the inner ring of the limiting member. The limiting member has a third groove and a fourth groove. The fourth groove is recessed in the inner ring wall of the limiting member. The fourth groove is annular and is used to accommodate and limit the second bearing component. By designing the limiting member as annular and opening an annular fourth groove in its inner ring wall, the third groove is used to reduce weight and position the installation, and the fourth groove is used to accurately accommodate and limit the second bearing component. This achieves the goal of optimizing weight and space while ensuring structural strength, and ensuring the stability of bearing installation and the concentricity of shaft rotation.

[0012] Preferably, the diameter of the second pulley is smaller than that of the first pulley, and the diameter of the second wheel body is larger than that of the second pulley. By making the diameter of the second pulley smaller than that of the first pulley and the diameter of the second wheel body larger than that of the second pulley, the difference in diameter between the pulley and the wheel body is utilized to further reduce speed and increase torque in the two-stage transmission. This achieves extremely low rotational speed and significantly amplified torque after two-stage reduction, meeting the requirements of high torque pulling force.

[0013] Preferably, the diameter of the first wheel body is equal to the diameter of the second pulley, the diameter of the first pulley is equal to the diameter of the second wheel body, the rotation axis of the first wheel body coincides with the rotation axis of the second wheel body, and the rotation axis of the first pulley coincides with the rotation axis of the second pulley. The stopper of the tensioning mechanism is used to abut against the middle of the first and second belts. The upper surfaces of the first and second belts overlap in the projection perpendicular to the direction of movement of the stopper. The stopper contacts the first and second belts in the overlapping projection area. By making the diameters of the first pulley and the second pulley equal, and the diameters of the first pulley and the second pulley equal, and by aligning the two sets of rotation axes, while the stopper contacts the middle of the first and second belts in the overlapping projection area, a symmetrical and compact two-stage deceleration layout is constructed. This achieves a balanced distribution of transmission force and allows a single stopper to tension the two transmission belts simultaneously at the most effective angle, optimizing space utilization and improving tensioning efficiency.

[0014] Preferably, the stop member includes a second shaft and two rollers rotatably mounted on the second shaft. A first bearing is provided between the rollers and the second shaft. The length of the rollers is equal to the width of the belt in the reduction mechanism. The two rollers are used to cooperate with the two belts in the reduction mechanism. Two second grooves are provided, located at both ends of the second housing along its length. These grooves are used to limit the two ends of the second shaft. By designing the stop to include the second shaft and two rollers mounted via the first bearing, with the roller length equal to the belt width, and using the two second grooves at both ends of the second housing to limit the ends of the second shaft, the belt is tensioned using rolling contact instead of sliding friction. This significantly reduces frictional resistance and wear during the tensioning process. The two rollers independently and evenly tension the two belts, ensuring uniform force distribution on the belts and preventing belt deviation.

[0015] Preferably, the elastic component includes a first elastic element and a second elastic element. The first elastic element is located between the two rollers, and its two working ends act on the middle of the second housing and the second shaft, respectively. There are two second elastic elements, which are located on opposite sides of the two rollers, and their two working ends act on the ends of the second housing and the second shaft, respectively. By setting the first elastic element between the two rollers and the two second elastic elements on the outside of the rollers, and having them act on different parts of the second housing and the second shaft, a three-point elastic support is provided for the second shaft, which is located in the middle and at both ends. This achieves balanced and stable force application to the stop and the rollers, ensuring that the two transmission belts obtain continuous and uniform tension, and effectively compensating for the slack caused by stretching or vibration of the transmission belts, thus maintaining constant tension in the transmission system.

[0016] The beneficial effects of this invention are: This low-power, high-torque resistance band structure integrates a drive unit, a reduction mechanism, and a drum within a first housing, and incorporates a tensioning mechanism including elastic components and stoppers. This achieves high torque output with low power input, ensuring stable and powerful resistance training results even under limited power conditions. Simultaneously, the reduction mechanism utilizes a pulley and belt transmission system, combined with the continuous elastic tension of the belt by the tensioning mechanism, effectively suppressing slippage, vibration, and belt slack during transmission. This significantly improves transmission smoothness, reliability, and service life, allowing the overall structure to balance high torque output and long-term operational stability within a compact layout. It is suitable for applications in strength training equipment where space, power consumption, and resistance performance are all critical. Attached Figure Description

[0017] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. The accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0019] Figure 1 This is a schematic diagram of the low-power, high-torque tensioner structure of the present invention; Figure 2 This is a schematic diagram of the internal structure of the low-power, high-torque tensioner structure of the present invention; Figure 3 This is a partial structural schematic diagram of the tensioning mechanism of the present invention; Figure 4 This is a schematic diagram of the internal structure of the first housing of the present invention, showing the deceleration mechanism; Figure 5 This is a schematic diagram of the internal structure of the first housing of the present invention, showing an exploded view of the deceleration mechanism; Figure 6 This is a schematic diagram of the structure of the limiting component of the present invention; Figure 7 This is a schematic diagram of the structure of the second housing of the present invention; Figure 8 This is a schematic diagram of the cross-sectional structure of the rod body of the present invention; Figure 9 This is an exploded view of the present invention when the driving component is an external rotor motor; Figure 10 This is one of the structural schematic diagrams of the low-power, high-torque tensioner structure of the present invention mounted on the frame; Figure 11 This is the second schematic diagram of the low-power, high-torque tensioner structure of the present invention installed on the frame. Figure 12 This is an exploded view of the structure of the low-power, high-torque tensioner of the present invention, wherein the driving component is an internal rotor motor; Figure 13 This is a cross-sectional structural diagram of the drive component of the present invention when it is an internal rotor motor.

[0020] The reference numerals in the figures include: 1. First housing; 2. Drive component; 3. Drum; 4. Reduction mechanism; 5. Tensioning mechanism; 6. Second housing; 7. Frame; 11. Ventilation slot; 12. Rod; 121. First rod section; 122. Second rod section; 1221. First through slot; 1222. Second through slot; 13. Seventh slot; 14. Eighth slot; 21. First wheel; 31. Second wheel; 32. Third bearing component; 40. Transmission belt; 401. First belt; 402. Second belt; 41. Pulley assembly; 411. Limit Positioning component; 4111, Third groove; 4112, Fourth groove; 412, First shaft; 413, Second bearing component; 414, First pulley; 415, Second pulley; 51, Elastic component; 511, First elastic component; 512, Second elastic component; 52, Stopping component; 521, Second shaft; 522, Roller; 523, First bearing component; 60, Protrusion; 601, Fifth groove; 61, First groove; 62, Second groove; 63, Sixth groove; 71, Bearing plate; 72, Fixed pulley. Detailed Implementation

[0021] The technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings.

[0022] In the description of this application, terms such as "first" and "second" are used only to distinguish different objects, not to describe a specific order. Furthermore, unless otherwise stated, " / " means "or," for example, A / B can mean A or B. "And / or" in this document is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A alone, A and B simultaneously, and B alone. Additionally, "at least one" refers to one or more, and "multiple" refers to two or more. "At least one of the following" or similar expressions refer to any combination of these items, including any combination of single or multiple items. For example, at least one of a, b, or c can represent: a, b, c; a and b; a and c; b and c; or a and b and c. Where a, b, and c can be single or multiple.

[0023] The terms “comprising” and “having”, and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the steps or units listed, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such process, method, product, or apparatus.

[0024] In this application, the words "exemplary" or "for example" are used to indicate that something is an example, illustration, or illustration. Any embodiment or design described as "exemplary," "for example," or "for example" in this application should not be construed as being more preferred or advantageous than other embodiments or designs. Rather, the use of the words "exemplary," "for example," or "for example" is intended to present the relevant concepts in a specific manner.

[0025] It is understood that in this application, "when," "if," and "if" all refer to the device making a corresponding action under certain objective circumstances, and are not time-limited, nor do they require the device to make a judgment action when it is implemented, nor do they imply any other limitations.

[0026] In this application, the use of singular designations for elements is intended to represent "one or more" rather than "one and only one," unless otherwise specified.

[0027] It is understood that in the embodiments of this application, "B corresponding to A" means that there is a correspondence between A and B, and B can be determined based on A. Determining B based on A does not mean that B can be determined solely based on A; B can also be determined based on A and / or other information.

[0028] Example 1 Reference Figures 1 to 11 A low-power, high-torque tensioner structure includes a first housing 1 and a drive member 2 disposed within the first housing 1. The first housing 1 also includes a drum 3 and a reduction mechanism 4. The drum 3 is used to wind a tension rope for use by external personnel. The drive member 2 is connected to the drum 3 via the reduction mechanism 4, which reduces the output speed of the drive member 2 and amplifies the output torque. The structure also includes a tensioning mechanism 5. The reduction mechanism 4 includes a pulley assembly 41 and a transmission belt 40 disposed on the pulley assembly 41. The transmission belt 40 is used in conjunction with the reduction mechanism 4 and the drive member 2 and / or with the drum 3. The transmission belt 40 has several wedge-shaped protrusions. The tensioning mechanism 5 includes an elastic component 51 and a stop member 52. The elastic component 51 applies force to the stop member 52, causing the stop member 52 to abut against the transmission belt 40, thereby applying tension to the transmission belt 40.

[0029] Several wedge-shaped protrusions are arranged in an array. The cross-sectional shape of the wedge-shaped protrusions is trapezoidal or triangular, and the corresponding wheel body and pulley are provided with corresponding grooves.

[0030] The transmission belt 40 can also be a V-belt.

[0031] With the above-described structural design, this low-power, high-torque resistance band integrates a drive unit 2, a reduction mechanism 4, and a drum 3 within the first housing 1. It also incorporates a tensioning mechanism 5, including an elastic component 51 and a stop component 52, achieving high torque output with low power input. This ensures stable and powerful resistance training even under limited power conditions. Simultaneously, the reduction mechanism 4 uses a pulley system and a drive belt 40, combined with the continuous elastic tension of the drive belt 40 by the tensioning mechanism 5. This effectively suppresses slippage, vibration, and belt slack during transmission, significantly improving transmission smoothness, reliability, and service life. The overall structure achieves both high torque output and long-term operational stability within a compact layout, making it suitable for applications in strength training equipment where space, power consumption, and resistance performance are all critical.

[0032] The speed reduction mechanism 4 also includes a fan located in the first housing 1. The fan is used to cool the pulley assembly 41, the first pulley 414, and the second pulley 415. Both ends of the first housing 1 in the length direction are hollowed out, and filters can be installed therein.

[0033] The fan is located in the ventilation slot 11. The rotation axis of the fan coincides with the rotation axis of the first pulley 414 and the second pulley 415. The fan is used to connect to an external power source or to be fixed relative to the first pulley 414 and the second pulley 415 so as to achieve rotation to drive the reduction mechanism 4 to cool down.

[0034] The drive component 2 is an external rotor motor. The first housing 1 is formed by drawing holes in aluminum profile. Holes are opened on the first housing 1 to house the drive component 2 and the drum 3 in one cavity. The middle is fixed by the rod body 12, end caps and cylinder. There are two end caps, which are located at both ends of the rod body 12 along its length. The cylinder is located in the middle of the rod body 12 to achieve concentricity and increase product life. Another hole is opened on the first housing 1 to fix the limiting component 411. The two holes for product installation are integrally formed, which also has high precision and long life. Fans are installed at both ends of the hole used to fix the limiting component 411 to reduce the internal structure temperature and prevent the multi-wedge belt from softening and aging prematurely due to high temperature under long-term rotational force, thus reducing its service life.

[0035] Two fans are provided. The first housing 1 has a wind tunnel for accommodating the two fans, the first pulley 414, the second pulley 415, and the limiting member 411. The wind tunnel is a straight through hole opened on the first housing 1. The limiting member 411 or the first housing 1 has a ventilation hole communicating with the wind tunnel. The two fans are located at both ends of the first housing 1 along its length and are used for blowing and sucking air, respectively. The wind tunnel is sealed or semi-sealed in the first housing 1 to form an effective airflow, thereby significantly improving the heat dissipation efficiency.

[0036] Ventilation duct 11 is connected to and collinear with the wind tunnel.

[0037] This structure integrates all components within the first housing, requiring only bolt fixing for installation. This improves assembly efficiency and reduces transportation complexity. The tensioner requires low-speed, high-torque products, and high torque necessitates more rare-earth magnets. Rare earth is a non-renewable resource. This invention, while ensuring smooth product operation and maintaining the same high torque output, uses multi-stage speed reduction to replace the original high-power direct-drive motor with a smaller motor (N times smaller), thus saving costs and increasing market competitiveness.

[0038] The first housing 1 is also provided with a seventh groove 13, which allows outside air to pass through the internal space of the first housing 1 and promotes heat dissipation of the internal structure of the first housing 1.

[0039] The tensioner structure also includes a frame 7, on which a support plate 71 is provided. The first housing 1 is detachably mounted on the support plate 71. The frame 7 is also provided with a fixed pulley 72. The tension rope wound on the drum 3 is used to pass through the fixed pulley 72 and has a handle at the end. It is worth noting that the first housing 1 is provided with a clearance groove for the tension rope wound on the drum 3 to pass through.

[0040] The bearing plate 71 is provided with a limiting protrusion. The free end of the limiting protrusion is large and trapezoidal. The first housing 1 is provided with an eighth groove 14. There are two limiting protrusions. After the limiting protrusions pass through the eighth groove 14, the first housing 1 is limited and can only slide relative to the bearing plate 71.

[0041] In this technical solution, the first housing 1 can also be welded to the support plate 71 after the sliding position of the first housing 1 relative to the support plate 71 is limited.

[0042] The support plate 71 is fixedly mounted on the frame 7. A channel for air circulation is provided between the support plate 71 and the frame 7. A heat sink can be installed on the side of the support plate 71 closest to the frame 7.

[0043] Specifically, the tensioning mechanism 5 also includes a second housing 6 detachably mounted on the first housing 1. The second housing 6 has a first groove 61 for accommodating the elastic component 51 and a second groove 62 for limiting the movement path of the stop member 52. The second groove 62 is strip-shaped, and its length direction is parallel to the movement direction of the stop member 52. The elastic component 51 has two working ends, which are used to abut the groove arm of the first groove 61 and the stop member 52, respectively, and to allow the stop member 52 to move along the length direction of the second groove 62. The first groove 61 for accommodating the elastic component 51 and the strip-shaped second groove 62 for limiting the movement path of the stop member 52 on the second housing 6 provide an installation position for the tensioning mechanism 5. The strip-shaped second groove 62 ensures that the stop member 52 moves linearly in a predetermined direction, realizing precise guidance and control of the direction of the elastic tension force, thereby improving the reliability and consistency of the tensioning action.

[0044] The second housing 6 is provided with a ventilation slot 11. The second housing 6 and the first housing 1 are fixed together by bolts. The second housing 6 and the first housing 1 are formed by integral construction or integral injection molding, respectively.

[0045] The outer surfaces of both the first housing 1 and the second housing 6 may be provided with heat sinks.

[0046] Specifically, a rod 12 is fixedly installed inside the first housing 1, and the driving component 2 is an external rotor motor installed on the rod 12. The output end of the driving component 2 is provided with a first wheel 21. The reduction mechanism 4 includes a first pulley 414 rotatably disposed relative to the first housing 1. The diameter of the first pulley 414 is larger than the diameter of the first wheel body 21. The transmission belt 40 includes a first belt body 401 with wedge-shaped protrusions. The first wheel body 21 is connected to the first pulley 414 via the first belt body 401. The stop member 52 of the tensioning mechanism 5 abuts against the first belt body 401. By setting the driving member 2 as an external rotor motor on the rod 12 and setting the first wheel body 21 at its output end, together with the larger diameter first pulley 414 and the first belt body 401 connecting the two, a first-stage reduction transmission is formed. The stop member 52 of the tensioning mechanism 5 abuts against the first belt body 401, and the tensioning ensures the high efficiency and stability of the first-stage belt transmission, thereby effectively increasing the system output torque and preventing slippage within a limited space.

[0047] A bearing can also be installed between the first wheel body 21 and the rod body 12.

[0048] The rotation axis of the first pulley 414 is not collinear with the rotation axis of the first wheel body 21.

[0049] Specifically, the drum 3 is rotatably mounted on the rod 12 and located at the end away from the drive member 2, and a second wheel 31 is provided on the outer periphery of the end of the drum 3 close to the drive member 2; The reduction mechanism 4 also includes a second pulley 415, which is fixedly disposed relative to the first pulley 414. The transmission belt 40 includes a second belt body 402 with a wedge-shaped protrusion. The second wheel body 31 is connected to the second pulley 415 via the second belt body 402. The stop member 52 of the tensioning mechanism 5 abuts against the second belt body 402. By setting the second wheel body 31 at one end of the drum 3 and setting the second pulley 415 fixed to the first pulley 414, the second belt body 402 connects the second wheel body 31 and the second pulley 415, forming a second-stage reduction transmission. The stop member 52 also abuts against the second belt body 402, which plays the role of using the two-stage belt transmission to perform secondary reduction and further amplify the torque finally output to the drum 3. At the same time, the two-stage transmission belts are synchronously tensioned via the stop member 52, realizing the simplification of the transmission system structure and the balanced distribution of the overall tension force, ensuring smooth and synchronous transmission between the two stages.

[0050] Specifically, the first pulley 414 and the second pulley 415 are both mounted on the pulley assembly 41. The pulley assembly 41 includes a limiting member 411 and a first shaft 412 rotatably mounted on the limiting member 411. The limiting member 411 is annularly arranged. A second bearing member 413 for supporting the rotation of the first shaft 412 is provided between the first shaft 412 and the limiting member 411. The limiting member 411 is fixedly mounted on the first housing 1. The first pulley 414 and the second pulley 415 are respectively located at both ends of the first shaft 412 along its length. By setting up a pulley assembly 41 including a limiting member 411, a first shaft 412, and a second bearing member 413, and fixing the first pulley 414 and the second pulley 415 to both ends of the first shaft 412, the pulleys of the two-stage reduction gears are integrated into an independent module that can be installed as a whole. The limiting member 411 is used to fix it to the first housing 1, and the second bearing member 413 supports the rotation of the first shaft 412. This achieves modular and highly coaxial installation of the reduction mechanism 4, improving assembly efficiency and transmission accuracy.

[0051] Two second bearing components 413 are provided.

[0052] The rod body 12 includes a first rod portion 121 and a second rod portion 122. The first rod portion 121 and the second rod portion 122 are integrally formed or integrally injection molded. A spacer is fixedly provided on the first rod portion 121 and the second rod portion 122. The first rod portion 121 and the second rod portion 122 are integrally formed with the spacer. The thickness of the spacer is equal to the thickness of the pulley assembly 41. The spacer is located between the first belt body 401 and the second belt body 402.

[0053] The isolation component has threaded holes, and the isolation component is fixed to the second housing 6 via the threaded holes and external bolts.

[0054] A third bearing 32 is provided between the drum 3 and the first rod 121, and the drum 3 is mounted on the first rod 121 via the third bearing 32.

[0055] Specifically, the limiting member 411 is annular, and the first shaft 412 is rotatably disposed on the inner ring of the limiting member 411. The limiting member 411 has a third groove 4111 and a fourth groove 4112. The fourth groove 4112 is recessed on the inner ring wall of the limiting member 411. The fourth groove 4112 is annular and is used to accommodate and limit the second bearing member 413. By designing the limiting member 411 as annular and opening the third groove 4111 on its outer ring wall and the annular fourth groove 4112 on its inner ring wall, the third groove 4111 is used to reduce weight and position the installation, and the fourth groove 4112 is used to accurately accommodate and limit the second bearing member 413. This achieves the goal of optimizing weight and space while ensuring structural strength, and ensuring the stability of bearing installation and the concentricity of shaft rotation.

[0056] The third groove 4111 is a threaded groove. The first housing 1 has a second threaded groove for use with the third groove 4111. The second threaded groove is recessed from the inner wall of the first housing 1. The threaded groove and the second threaded groove can be limited by external bolts. There are two third grooves 4111, which are located at the upper and lower ends of the limiting member 411.

[0057] Specifically, the diameter of the second pulley 415 is smaller than that of the first pulley 414, and the diameter of the second wheel body 31 is larger than that of the second pulley 415. By making the diameter of the second pulley 415 smaller than that of the first pulley 414 and the diameter of the second wheel body 31 larger than that of the second pulley 415, the difference in diameter between the pulleys and the wheel body is used to further reduce speed and increase torque in the two-stage transmission. This achieves that after two-stage reduction, the drum 3 obtains extremely low speed and significantly amplified torque, meeting the requirements of high torque pulling force.

[0058] It is worth noting that in this technical solution, the outer periphery of the wheel body and pulley is provided with a wedge, the belt body is a multi-wedge belt with corresponding teeth, and the inner ring of the multi-wedge belt is provided with a wedge-shaped protrusion with corresponding teeth.

[0059] Specifically, the diameter of the first wheel body 21 is equal to the diameter of the second pulley 415, the diameter of the first pulley 414 is equal to the diameter of the second wheel body 31, the rotation axis of the first wheel body 21 coincides with the rotation axis of the second wheel body 31, and the rotation axis of the first pulley 414 coincides with the rotation axis of the second pulley 415. The stop member 52 of the tensioning mechanism 5 is used to abut against the middle position of the first belt body 401 and the second belt body 402. The upper surfaces of the first belt body 401 and the second belt body 402 overlap in the projection perpendicular to the direction of movement of the stop member 52. The stop member 52 contacts the first belt body 401 and the second belt body 402 in the overlapping projection area. By making the diameters of the first pulley 21 and the second pulley 415 equal, and the diameters of the first pulley 414 and the second pulley 31 equal, and the two sets of rotation axes coincide, while the stop member 52 contacts the middle of the first belt body 401 and the second belt body 402 in the overlapping projection area, a symmetrical and compact two-stage deceleration layout is constructed, the transmission force is balanced, and a single stop member 52 can tension the two transmission belts at the most effective angle at the same time, optimizing space utilization and improving tensioning efficiency.

[0060] The aforementioned stopper 52 contacts the first belt 401 and the second belt 402 in the projected overlapping area, that is, it is provided in the middle of the first belt 401 and the second belt 402. In other words, the two rollers 522 mentioned below can contact the first belt 401 and the second belt 402 at the same height.

[0061] Specifically, the stop member 52 includes a second shaft 521 and two rollers 522 rotatably mounted on the second shaft 521. A first bearing member 523 is provided between the rollers 522 and the second shaft 521. The length of the rollers 522 is equal to the width of the belt in the reduction mechanism 4. The two rollers 522 are used to cooperate with the two belts in the reduction mechanism 4. Two second grooves 62 are provided, and the two second grooves 62 are located at both ends of the length direction of the second housing 6. The two ends of the second shaft 521 are limited by the two second grooves 62. By designing the stop member 52 to include the second shaft 521 and two rollers 522 installed by the first bearing member 523, and the length of the rollers 522 is equal to the width of the belt, and by using the two second grooves 62 at both ends of the second housing 6 to limit the ends of the second shaft 521, the transmission belt is tensioned by using rolling contact instead of sliding friction, which greatly reduces the frictional resistance and wear during the tensioning process. The two rollers 522 are respectively used to independently and evenly tension the two belts, ensuring that the belt is subjected to uniform force and is not prone to deviation.

[0062] The diameter of the roller body 522 is larger than the diameter of the second shaft body 521.

[0063] The two rollers 522 have a high friction coefficient layer on their circumferential surfaces, such as rubber silicone material. Furthermore, concave or convex points can be set on the circumferential surfaces of the rubber silicone material to further increase friction. Of course, the first elastic element 511 mentioned below can also be omitted, and a connecting rod can be set between the two rollers 522 so that the two rollers 522 can rotate synchronously.

[0064] Specifically, the elastic component 51 includes a first elastic element 511 and a second elastic element 512. The first elastic element 511 is located between the two rollers 522, and its two working ends act on the middle of the second housing 6 and the second shaft 521, respectively. There are two second elastic elements 512, which are located on the side of the two rollers 522 that are far apart from each other. The two working ends of the second elastic elements 512 act on the ends of the second housing 6 and the second shaft 521, respectively. By setting the first elastic element 511 between the two rollers 522 and the two second elastic elements 512 on the outside of the rollers 522 (i.e., the side far from the middle), and making them act on different parts of the second housing 6 and the second shaft 521, the second shaft 521 is provided with three-point elastic support at the middle and both ends. This achieves balanced and stable force application to the stopper 52 and the rollers 522, ensuring that the two transmission belts obtain continuous and uniform tension, and effectively compensating for the slack caused by the stretching or vibration of the transmission belts, thus maintaining constant tension in the transmission system.

[0065] The second housing 6 is disposed on the first housing 1. The second housing 6 is used to accommodate the limiting tensioning mechanism 5. A protrusion 60 is provided at the middle position of the second housing 6. The protrusion 60 extends from the second housing 6 toward the side closer to the first housing 1. The first groove 61 is opened on the protrusion 60 to accommodate the first elastic member 511 in the elastic component 51.

[0066] After installation, the protrusion 60 is located between the two rollers 522. The protrusion 60 has two fifth grooves 601 that are connected to the first groove 61. Correspondingly, the two fifth grooves 601 are collinear with the two second grooves 62 on the second housing 6. The two fifth grooves 601 and the two second grooves 62 on the second housing 6 are used to limit the second shaft 521, respectively, to limit the middle and end of the second shaft 521.

[0067] The second housing 6 also has a sixth groove 63 that communicates with the second groove 62. The sixth groove 63 is used to accommodate the second elastic member 512 in the elastic component 51. The radial dimension of the second elastic member 512 is smaller than the radial dimension of the first elastic member 511.

[0068] Example 2 Embodiment 2 of this application mainly introduces the structure of a low-power, high-torque tensioner and the main structure of its internal drive component 2.

[0069] Embodiment 2 of this application can be implemented alone or in combination with Embodiment 1 described above, and this application does not impose any restrictions.

[0070] Reference Figures 1 to 11 A low-power, high-torque tensioner structure includes a first housing and a drive unit disposed within the first housing. The first housing also includes a drum and a reduction mechanism. The drum is used to wind a tension rope for use by external personnel. The drive unit is connected to the drum via the reduction mechanism. The reduction mechanism is used to reduce the output speed of the drive unit and amplify the output torque. The structure also includes a tensioning mechanism. The reduction mechanism includes a pulley assembly and a transmission belt disposed on the pulley assembly. The tensioning mechanism includes an elastic component and a stop component. The elastic component applies a force to the stop component, causing the stop component to abut against the transmission belt to apply tension to the transmission belt.

[0071] The driving component includes a second rod, a tube rotatably disposed with the second rod, and a stator disposed on the second rod and located within the tube. The tube also contains several magnetic tiles arranged around the central axis of the tube. It also includes an end cap, with an extension at the end of the tube along its length. The end cap has a ninth groove for accommodating the extension. The bent extension limits the end cap to the tube. The end cap is installed in conjunction with the tube via the extension and the ninth groove for accommodating the extension. The tube, end cap, and several magnetic tiles are fixedly connected together to form an outer rotor.

[0072] The tube body is an approximately cylindrical cylinder, and the magnetic tile can be a permanent magnet in a broad sense. The end cap is set in a circular shape corresponding to the tube body and installed at the end of the tube body along its length.

[0073] Specifically, a fourth bearing is provided between the second rod and the end cover, and an electromagnetic component is provided on the second rod. The second rod and the electromagnetic component form a stator for use with the outer rotor. By setting a relatively rotating second rod in the tube and setting a fourth bearing between the second rod and the end cover, the second rod can rotate smoothly relative to the outer rotor composed of the tube, end cover and magnetic tile in a low-friction and high-precision manner. At the same time, the electromagnetic component is set on the second rod, which interacts with the magnetic tile in the outer rotor to generate electromagnetic force, thereby realizing the construction of the core drive function of the motor and transforming the structural assembly into a precisely controllable rotary motion output.

[0074] Specifically, the extension and the tube body are an integral structure or integrally injection molded. Several extensions are provided and arranged in a ring array at the end of the tube body along its length. The end cap includes an insert and a stop. The insert is used to extend into the tube body, and the stop is used to stop the end of the tube body along its length. When the end cap is on the tube body, the extension is bent to limit the end cap. By designing the extension and the tube body as an integral structure (or integrally injection molded) and arranging multiple extensions in a ring array at the end of the tube body, the connection between the extension and the tube body has high structural strength and integrity, avoiding loosening or misalignment that may be caused by separate assembly. This provides multiple stable, reliable and evenly distributed connection points for the installation of the end cap, thereby enhancing the rigidity of the outer rotor main structure and improving the assembly reference accuracy.

[0075] In this embodiment, the extension and the tube are made of aluminum alloy and are formed by stretching.

[0076] The diameter of the stop part is not less than the diameter of the embedded part.

[0077] Specifically, several ninth slots are provided and arranged in a circular array on the circumference of the end cover. The ninth slot includes a first slot and a second slot. The first slot and the second slot accommodate extensions to limit the rotation of the end cover along the central axis of the tube and to limit the movement of the end cover along the central axis of the tube, respectively. By setting the first slot and the second slot in the ninth slot and accommodating the extensions to limit the rotation and movement of the end cover along the central axis of the tube, precise positioning and rigid locking of the end cover and the tube in two degrees of freedom, circumferential and axial, are achieved. This effectively prevents the relative displacement or loosening of the end cover that may occur during motor operation and ensures the structural integrity and operational stability of the outer rotor as an integral component.

[0078] The first slot is mainly opened in the embedding part and partly opened in the stopping part. The second slot is opened in the stopping part. In this embodiment, the second slot is connected to the third slot mentioned below.

[0079] Specifically, the end cover has a third slot arranged in a ring array. The third slot extends through the end cover along its thickness direction and is arc-shaped. By opening the third slot in a ring array and arc shape on the end cover, the end cover can achieve partial material removal while meeting structural strength requirements. This results in multiple effects, including reducing the overall weight of the end cover, optimizing rotational inertia, and promoting airflow inside the motor to assist in heat dissipation.

[0080] Specifically, the end cover includes a first cover body, with a fourth slot on the side of the first cover body near the tube body. A magnetic element is installed in the fourth slot, and a position detection element is installed on the side of the second rod near the magnetic element. The position detection element measures the phase angle or rotational speed of the outer rotor by detecting the change in the magnetic field generated by the magnetic element. By opening a fourth slot and installing a magnetic element on the first cover body, and simultaneously installing a position detection element at a corresponding position on the second rod, the position detection element detects the change in the magnetic field generated by the magnetic element that rotates synchronously with the outer rotor, realizing non-contact, high-precision measurement of the real-time phase angle or rotational speed of the outer rotor, providing a key speed or position feedback signal for the closed-loop control of the motor.

[0081] The second rod has several threaded holes at one end, which are used for external screw limit position detection elements. The position detection elements can be Hall sensors.

[0082] Specifically, the motor structure also includes a first wheel body located on the side of the first cover away from the tube body.

[0083] Specifically, the end cap also includes a second cover body, which is located at the end of the tube body away from the first cover body. The second cover body has a through hole, and the end of the second rod portion away from the first cover body protrudes through the through hole and extends out of the second cover body. The end of the second rod portion away from the first cover body is used to limit it to the outside or to the second rod portion. By setting the second cover body at the other end of the tube body and opening a through hole on it for the end of the second rod portion to pass through and be limited to the outside, radial support and axial positioning of the other end of the second rod portion are achieved. Together with the fourth bearing component on the side of the first cover body, it forms a two-point support system for the second rod portion, which improves the coaxiality and running stability of the rotor system, and at the same time provides an interface for external installation or transmission for the second rod portion.

[0084] The through hole is circular.

[0085] Specifically, a first through slot 1221 is provided on the second rod 122. The first through slot 1221 is a through hole that passes through the second rod 122 axially. The first through slot 1221 is used for the wiring of the position detection element. By providing the first through slot 1221 axially through the second rod 122, a built-in, protected wiring channel is provided for the wiring of the position detection element (such as a Hall sensor). This realizes the function of orderly leading out the detection signal line from the rotating part inside the motor, avoiding interference, wear or mess that may be caused by external wiring, and improving the neatness and reliability of the wiring inside the motor.

[0086] Specifically, a second through slot 1222 communicating with the first through slot 1221 is also provided on the second pole. The second through slot 1222 can be used for the wiring required by the electromagnetic components. By providing a dedicated wiring channel for the power supply and control lines of the electromagnetic components that is independent and separate from the detection lines, the power lines and signal lines are laid out separately inside the second pole, which effectively reduces electromagnetic interference between the lines and further optimizes the internal space utilization and wiring order.

[0087] The reason why this technical solution does not use gears and chains is that the gap difference between gears and chains will cause users to experience uneven pulling when pulling the tension rope.

[0088] Example 3 Embodiment 3 of this application mainly introduces the structure of a low-power, high-torque tensioner and its internal drive component 2 as the main structure of an internal rotor motor.

[0089] Embodiment 3 of this application can be implemented alone or in combination with the aforementioned Embodiments 1 and 2. This application does not impose any restrictions.

[0090] Reference Figures 1 to 13 A low-power, high-torque tensioner structure includes a first housing and a drive unit disposed within the first housing. The first housing also includes a drum and a reduction mechanism. The drum is used to wind a tension rope for use by external personnel. The drive unit is connected to the drum via the reduction mechanism. The reduction mechanism is used to reduce the output speed of the drive unit and amplify the output torque. The structure also includes a tensioning mechanism. The reduction mechanism includes a pulley assembly and a transmission belt disposed on the pulley assembly. The tensioning mechanism includes an elastic component and a stop component. The elastic component applies a force to the stop component, causing the stop component to abut against the transmission belt to apply tension to the transmission belt.

[0091] The driving component includes a second rod portion, a tube body rotatably disposed with the second rod portion, a rotor disposed on the second rod portion and located within the tube body, and a stator disposed on the tube body; it also includes an end cap, an extension portion provided at the end of the tube body along its length, a ninth groove provided on the end cap for accommodating the extension portion, the bent extension portion limiting the end cap and the tube body together, and the end cap being installed in conjunction with the tube body via the extension portion and the ninth groove for accommodating the extension portion.

[0092] A rod 12 is rotatably mounted on the first housing 1, and a drum 3 is rotatably mounted on the rod 12. A drive unit 2 is fixedly mounted on the first housing 1, and a first wheel 21 is provided at the output end of the drive unit 2 for driving the drum 3 to rotate via a reduction mechanism 4.

[0093] It is worth noting that the drive unit 2 used in this embodiment is a brushless motor.

[0094] When the drive component 2 is an external rotating motor, the drive component 2 is directly mounted on the rod body 12. When the drive component 2 is an internal rotating motor, the drive component 2 is mounted on the first housing 1, and the rod body 12 is only used to support the drum 3.

[0095] The above descriptions provide one or more embodiments in conjunction with specific details, but do not imply that the specific implementation of the present invention is limited to these descriptions. Any methods or structures that are similar to or identical to those of the present invention, or any technical deductions or substitutions made based on the concept of the present invention, should be considered within the scope of protection of the present invention.

Claims

1. A low-power, high-torque tensioner structure, comprising a first housing (1) and a drive member (2) disposed in the first housing (1), the first housing (1) further comprising a drum (3) and a reduction mechanism (4), the drum (3) being used to wind a tension rope for use by external personnel, the drive member (2) being connected to the drum (3) via the reduction mechanism (4), the reduction mechanism (4) being used to reduce the output speed of the drive member (2) and amplify the output torque; characterized in that: It also includes a tensioning mechanism (5), which includes an elastic component (51) and a stop (52). The deceleration mechanism (4) includes a pulley assembly (41) and a drive belt (40). The drive belt (40) is used to cooperate with the deceleration mechanism (4) and the drive component (2) and / or the deceleration mechanism (4) and the drum (3). The elastic component (51) is used to apply force to the stop (52) so that the stop (52) abuts against the drive belt (40) to apply tension to the drive belt (40).

2. The low-power, high-torque tensioner structure according to claim 1, characterized in that: The tensioning mechanism (5) also includes a second housing (6) that can be detachably disposed on the first housing (1). The second housing (6) has a first groove (61) for accommodating the elastic component (51) and a second groove (62) for limiting the movement path of the stop (52). The second groove (62) is strip-shaped and its length direction is parallel to the movement direction of the stop (52). The elastic component (51) has two working ends. The two working ends of the elastic component (51) are used to stop the groove arm of the first groove (61) and the stop (52) respectively, and to allow the stop (52) to move along the length direction of the second groove (62).

3. The low-power, high-torque tensioner structure according to claim 1 or 2, characterized in that: The first housing (1) is also fixedly provided with a rod (12), and the driving component (2) is an external rotor motor provided on the rod (12). The output end of the driving component (2) is provided with a first wheel (21). The deceleration mechanism (4) includes a first pulley (414) rotatably disposed relative to the first housing (1). The diameter of the first pulley (414) is larger than the diameter of the first wheel body (21). The transmission belt (40) includes a first belt body (401) with wedge-shaped protrusions. The first wheel body (21) is connected to the first pulley (414) via the first belt body (401). The stop member (52) of the tensioning mechanism (5) abuts against the first belt body (401).

4. The low-power, high-torque tensioner structure according to claim 3, characterized in that: The drum (3) is rotatably mounted on the rod (12) and located at the end away from the drive member (2). A second wheel (31) is provided on the outer periphery of the end of the drum (3) close to the drive member (2). The deceleration mechanism (4) also includes a second pulley (415), which is fixed relative to the first pulley (414). The transmission belt (40) includes a second belt body (402) with a wedge-shaped protrusion. The second wheel body (31) is connected to the second pulley (415) via the second belt body (402). The stop member (52) of the tensioning mechanism (5) abuts against the second belt body (402).

5. The low-power, high-torque tensioner structure according to claim 4, characterized in that: The first pulley (414) and the second pulley (415) are both provided on the pulley assembly (41). The pulley assembly (41) includes a limiting member (411) and a first shaft (412) rotatably provided on the limiting member (411). A second bearing member (413) for supporting the rotation of the first shaft (412) is provided between the first shaft (412) and the limiting member (411). The limiting member (411) is fixedly provided on the first housing (1). The first pulley (414) and the second pulley (415) are respectively provided at both ends of the first shaft (412) in the length direction. The speed reduction mechanism (4) also includes a fan located in the first housing (1). The rotation axis of the fan coincides with the rotation axis of the first pulley (414) and the second pulley (415). The fan is used to cool the pulley assembly (41) and the first pulley (414) and the second pulley (415).

6. The low-power, high-torque tensioner structure according to claim 5, characterized in that: The limiting member (411) is annular, and the first shaft (412) is rotatably disposed on the inner ring of the limiting member (411). The limiting member (411) is provided with a third groove (4111) and a fourth groove (4112). The third groove (4111) is strip-shaped and recessed on the outer ring wall of the limiting member (411), and the fourth groove (4112) is recessed on the inner ring wall of the limiting member (411). The fourth groove (4112) is annular and is used to accommodate and limit the second bearing member (413).

7. The low-power, high-torque tensioner structure according to claim 4, characterized in that: The diameter of the second pulley (415) is smaller than that of the first pulley (414), and the diameter of the second wheel body (31) is larger than that of the second pulley (415).

8. The low-power, high-torque tensioner structure according to claims 4-7, characterized in that: The diameter of the first wheel (21) is equal to the diameter of the second pulley (415), the diameter of the first pulley (414) is equal to the diameter of the second wheel (31), the rotation axis of the first wheel (21) coincides with the rotation axis of the second wheel (31), and the rotation axis of the first pulley (414) coincides with the rotation axis of the second pulley (415). The stop (52) of the tensioning mechanism (5) is used to abut against the middle position of the first belt (401) and the second belt (402). The upper surfaces of the first belt (401) and the second belt (402) overlap in the projection perpendicular to the direction of movement of the stop (52). The stop (52) contacts the first belt (401) and the second belt (402) in the overlapping area of ​​the projection.

9. The low-power, high-torque tensioner structure according to claim 2, characterized in that: The stop member (52) includes a second shaft (521) and two rollers (522) rotatably mounted on the second shaft (521). A first bearing member (523) is provided between the rollers (522) and the second shaft (521). The length of the rollers (522) is equal to the width of the belt in the deceleration mechanism (4). The two rollers (522) are used to cooperate with the two belts in the deceleration mechanism (4). There are two second grooves (62), which are located at both ends of the second housing (6) along its length. The second housing (6) limits the two ends of the second shaft (521) via the two second grooves (62).

10. The low-power, high-torque tensioner structure according to claim 9, characterized in that: The elastic component (51) includes a first elastic element (511) and a second elastic element (512). The first elastic element (511) is located between two rollers (522). The two working ends of the first elastic element (511) act on the middle of the second housing (6) and the second shaft (521), respectively. There are two second elastic elements (512). The two second elastic elements (512) are located on the side of the two rollers (522) that are far apart. The two working ends of the second elastic elements (512) act on the ends of the second housing (6) and the second shaft (521), respectively.

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