Brake-Integrated Motor Roller Unit Layout for Easier Assembly

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Solution Overview

Problem

Existing motor incorporating rollers without a brake function are difficult to assemble due to the integration of a brake member, and existing brake-equipped rollers do not easily utilize a motor unit with a built-in circuit board.

Innovation Solution

A motor unit configuration that includes an outer cylinder incorporating a motor, brake member, and circuit board, with the brake member positioned between the motor and circuit board, allowing for easy assembly and integration of a brake function.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a brake member is integrated into the motor unit, then the brake function is incorporated into the motor incorporating roller, but the assembly becomes more difficult due to space constraints and component interference

Engineering Contradiction:

Improvebrake function integrationVSAvoidassembly difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The motor unit is divided into distinct functional modules: the motor (with rotor and stator), the brake member, and the circuit board, each positioned in specific zones within the outer cylinder. This segmentation allows independent assembly and positioning of each component, reducing assembly difficulty while maintaining brake function integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brake member is positioned in the radial direction between the motor and circuit board, utilizing the radial space within the outer cylinder rather than adding axial length. This dimensional arrangement accommodates the brake function without increasing the overall length of the motor unit, facilitating integration while managing space constraints.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Device complexity

If the brake member is positioned between the motor and circuit board, then power transmission configuration is simplified, but space for electrical connections becomes more constrained

Engineering Contradiction:

Improvepower transmission configurationVSAvoidspace for electrical connections

Core Design Contradiction:

Device complexityVSArea of stationary object

Solution Approach 1:

The circuit board is pre-wired to the motor and brake member before final assembly into the outer cylinder. This preliminary electrical connection setup allows for simplified power transmission configuration while ensuring that wiring space requirements are accounted for in the compact arrangement between the motor, brake member, and circuit board.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the motor unit is designed for easy assembly with integrated components, then versatility for different roller bodies is improved, but the structural rigidity for withstanding press-fit forces is reduced

Engineering Contradiction:

Improvecompatibility with different roller bodiesVSAvoidrigidity for press-fit

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The motor, brake member, and circuit board are merged into a single integrated motor unit that functions as one assembly module. This merged structure maintains internal flexibility for easy assembly and compatibility with different roller bodies, while the outer cylinder provides the necessary structural rigidity to withstand press-fit forces during installation.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS12476518B2Motor unit for motor incorporating roller, geared motor, and method for manufacturing the same

Publication Date: 2025.11.18 ITOH ELECTRIC COMPANY LIMITED

AI summary

A motor unit configured to be inserted into a separately prepared roller body to constitute a motor incorporating roller, comprising an outer cylinder, a motor, a brake member, and a circuit board, wherein the outer cylinder incorporates the motor, the brake member, and the circuit board, wherein the brake member is located between the motor and the circuit board in the outer cylinder, and wherein the circuit board is wired to the motor and the brake member in the outer cylinder.