Compact Brushless Motoreducer with Nested Gears
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Solution Overview
Problem
Existing geared motor solutions fail to achieve sufficient compactness, particularly in applications like automotive thermoregulation flaps, where a reduced footprint and better integration of motor and reducer are required, as they do not allow for a single, flat, and narrow box configuration with compact reduction assemblies.
Innovation Solution
A brushless electric motor is combined with a motion-reducing gear system where the first shaft carrying a pinion/toothed wheel assembly is placed between the electric coils, allowing for a compact design by grouping two sprocket/pinion assemblies on a single common axis, achieving high reduction ratios such as over 1:200.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate motor and reducer assemblies are used, then ease of manufacture is improved, but device compactness deteriorates
Solution Approach 1:
The patent merges the motor and reducer into a single integrated geared motor assembly, where the motor shaft directly drives the pinion gear. This consolidation eliminates the need for separate motor and reducer components, reducing the overall footprint while maintaining manufacturing feasibility through modular design of the integrated unit.
Solution Approach 2:
The patent nests the gear train components within the motor housing structure, placing the pinion, idler, and output gears in a compact arrangement inside the motor assembly. This nesting approach allows multiple functional components to occupy overlapping spatial volumes, significantly reducing the external footprint of the overall device.
2Power
If compact reduction assemblies with multiple pinion/toothed wheel assemblies per carrier shaft are used, then reduction ratio is improved, but device complexity increases
Solution Approach 1:
The patent segments the gear train into distinct functional stages: a pinion gear on the motor shaft, an idler gear for direction change, and an output gear on the output shaft. This segmentation allows each component to be optimized independently while maintaining overall compactness, achieving high reduction ratios without excessive complexity.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement of gears, positioning the idler gear to mesh with both the pinion and output gear in a compact configuration. By exploiting vertical and radial dimensions rather than only linear arrangement, the design achieves complex reduction ratios within a small footprint without proportionally increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a very compact geared motor assembly with high reduction ratios, achieving a smaller footprint and improved integration of motor and reducer, meeting the demands of specific applications like automotive thermoregulation flaps.
Implementation Method 1
a brushless-type electric motor (100) consisting of a wound stator assembly (1) which cooperates magnetically with a rotor (9)
Implementation Method 2
an input pinion (3) which meshes with a train of gears forming a mechanical motion reducer
Data Source
Figure 1~2a
Figure 2b~3a
Figure 3b~4
AI summary
The invention relates to a motoreducer consisting of a casing (16) comprising a brushless motor having at least two electrical phases, a rotor (9) rotating on an axle (2), and composed of a stator assembly (1) having at least two poles each bearing coils the winding axes of which are spaced apart by a mechanical angle smaller than 180° and extend radially, and a gear train, the gear train comprising: a first axle (4) placed in the angular space formed between the two poles, said first axle (4) bearing a first assembly formed by a coupled pinion (Pe1, Pe1h) and toothed wheel (Re1, Re1h), the toothed wheel (Re1, Re1h) being placed above the pinion (Pe1, Pe1h) and having a radius larger than the pinion (Pe1, Pe1h), the toothed wheel (Re1, Re1h) meshing with an input pinion (3) rotating on the axle (2) of the rotor (9), the toothed wheel (Re1, Re1h) being placed above said poles (14) bearing the coils, all the axles (4, 5, 6, 7) of the gear train being parallel to one another and parallel to the axle (2) of the rotor (9), characterised in that the gear train has at least one axle (4, 5) bearing two toothed wheels/pinion assemblies rotating on said axle (4,5).