Coreless Tubular Motor Transmission With Planetary Brake Reduction
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Solution Overview
Problem
Existing tubular motors face issues such as slow response, high energy consumption, vibration, limited torque, and poor transmission stability due to the presence of rotor cores and fixed magnetic shoes, as well as inadequate speed reduction ratios and compactness in their speed reducers.
Innovation Solution
A coreless tubular motor transmission structure is developed, featuring a primary gear ring connected to a motor main body with a coreless motor, a braking assembly with a brake mandrel and torsion spring, and a compact planetary gear assembly that increases torque and stability through the use of driving and driven jaws, and a circumferential fixation structure for improved speed reduction and braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If rotor cores and magnetic shoes are attached to the housing in ordinary rare-earth or ferrite motors, then the motor structure is stable, but the response speed is slow and energy consumption is high
Solution Approach 1:
The patent removes the rotor core from the motor structure, extracting the harmful component that causes eddy currents and high energy consumption. The coreless motor design eliminates the traditional rotor core while retaining the essential motor functions, directly resolving the contradiction between response speed and energy consumption.
2Temperature
If rotor cores are used in the motor, then the motor structure is complete, but eddy currents are generated causing motor heating and high energy consumption
Solution Approach 1:
The patent extracts and removes the rotor core that generates eddy currents. By eliminating the conductive rotor core material, the source of eddy current heating is removed, directly addressing the contradiction between motor heating and energy consumption.
3Force
If magnetic shoes (permanent magnets) are fixed on the housing with certain thickness, then the magnetic strength is sufficient, but the outer diameter of the motor rotors is greatly limited and output torque is limited
Solution Approach 1:
The patent repositions the permanent magnets from the housing to the rotor, and changes the magnet arrangement from axial thickness to radial thickness. This dimensional change allows the magnets to be placed where they can directly interact with the stator windings, increasing the lever arm for torque generation without increasing the overall motor outer diameter.
4Speed
If speed reducers are provided on tubular motors to reduce rotating speed, then the output shaft speed satisfies requirements, but the speed reducers cannot satisfy the requirements in term of speed reduction ratio and are not compact enough and poor in stability
Solution Approach 1:
The patent employs a planetary gear mechanism where planetary gears are nested within the motor structure, with the sun gear at the center, planetary gears orbiting around it, and a ring gear enclosing them. This nested arrangement achieves high speed reduction ratios in a compact space while maintaining transmission stability through the inherent mechanical advantages of planetary gear systems.
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 coreless design reduces energy consumption, increases response speed, enhances torque, and improves transmission stability and braking sensitivity, while maintaining a compact structure.
Implementation Method 1
a brake torsion spring, the two ends of which are bent outward in the radial direction
Data Source
AI summary
A transmission structure of a coreless tubular motor includes a motor main body, a motor connecting seat, a primary gear ring, a primary planetary gear assembly, a brake outer sleeve, a secondary planetary gear assembly and a tertiary planetary gear assembly; the motor main body is a coreless motor; a brake driving member and a brake driven member which are coaxially provided are provided in and pass through the brake outer sleeve; the brake driving member is connected to an output end of the primary planetary gear assembly, the brake driven member is connected to an input end of the secondary planetary gear assembly, the brake driving member is in transmission connection with the brake driven member, and a braking assembly connected to the brake driving member and the brake driven member is provided on the inner side of the brake outer sleeve in the circumferential direction.