Compact Drive Integrating Motor and Gear Unit
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Solution Overview
Problem
Existing compact drives are limited by large axial length and restricted power take-off options, with complex and costly interfaces between components, and inefficient heat dissipation, leading to increased size, weight, and manufacturing complexity.
Innovation Solution
A compact drive design integrating an electric motor, gear unit, and frequency converter within a central housing part, allowing for reduced axial length, two-sided power take-off, and efficient heat distribution through a central housing part, eliminating the need for additional machining and thermal barriers, and utilizing a spiroid gear unit for increased efficiency and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a compact drive integrates multiple drive components (electric motor, gear unit, frequency converter) in a conventional arrangement, then the axial length becomes large, but component integration and heat dissipation efficiency improve
Solution Approach 1:
The patent combines the electric motor, gear unit, and frequency converter into a single integrated housing structure. The motor housing serves simultaneously as the gear unit housing and frequency converter housing, merging three separate components into one unified structure. This integration eliminates the need for separate housings and reduces the overall axial length of the compact drive while maintaining functional independence of each component.
Solution Approach 2:
The patent arranges the frequency converter axially behind the motor blower in the axial direction, utilizing the existing air stream path for cooling. This dimensional arrangement allows the frequency converter to be positioned within the existing motor housing volume without increasing radial dimensions, thereby reducing overall axial length while providing adequate cooling through the motor's air stream.
2Volume of stationary object
If a frequency converter is axially mounted behind the motor blower and cooled by its air stream, then space requirements are reduced, but a fan is required to direct ambient air past the components
Solution Approach 1:
The motor blower's air stream is utilized to cool the frequency converter without requiring a separate cooling system. The air stream generated by the motor blower naturally flows past the frequency converter, providing passive cooling. This self-service approach eliminates the need for additional fans or complex cooling mechanisms, reducing both volume and operational complexity.
3Manufacturing precision
If multiple separate housing parts are used for motor and gear unit, then manufacturing precision requirements increase, but component modularity and maintenance ease improve
Solution Approach 1:
The patent merges the motor housing, gear unit housing, and frequency converter housing into a single integrated housing structure. This eliminates the need for precision-machined interfaces between separate housing parts, reducing manufacturing precision requirements. The unified housing is manufactured as a single piece or pre-assembled unit, eliminating interface complexity while maintaining component modularity through internal separations.
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 reduces axial length, enables flexible power take-off configurations, and optimizes heat dissipation, resulting in a more compact, efficient, and cost-effective drive unit with improved torque and speed performance across the entire speed range.
Implementation Method 1
Each drive component may be at least connected to the same central housing part for purposes of heat dissipation, and that the heat may therefore be distributed by it. Therefore, not only is each drive component's own housing utilizable for dissipating heat, but also the material region forming the housing for another component that is cooler at the same time.
Data Source
AI summary
In compact drive, spiroid gear unit, and method for manufacturing a drive unit that includes at least an electric motor, a brake, a gear unit, and a frequency converter, the output shaft of the gear unit and the rotor shaft are positioned in parallel to each other, and the shaft-center distance is determined by at least one gear stage. The first gear stage includes a first toothed member connected to the rotor shaft, and a second toothed member, which engages with the first toothed member and is connected to an intermediate shaft, the brake, including at least a brake-rotor shaft, being integrated in the housing of the compact drive, the brake-rotor shaft being parallel to the rotor shaft, and the brake-rotor shaft being connected to a toothed member, which engages with the second toothed member.