Coreless Tubular Motor Assembly for Fast Response and Stable Torque
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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 their rotor core structure and speed reducers, which restrict their performance and service life.
Innovation Solution
A tubular motor assembly using a coreless motor structure with a hollow steel tube body, a coreless motor main body, and a planetary gear assembly, where the permanent magnet is integrated within the rotor coil, and a brake mechanism with a torsion spring for improved torque and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a rotor core structure is used in tubular motors, then the motor can generate sufficient torque, but the response speed becomes slow and energy consumption increases
Solution Approach 1:
The patent removes the rotor core from the motor structure, retaining only the essential components needed for torque generation. This extraction of the harmful rotor core element eliminates the source of slow response and high energy consumption while preserving the torque-generating capability through the coreless motor design with permanent magnets directly mounted on the stator.
Solution Approach 2:
The patent replaces the traditional mechanical rotor core structure with a coreless electromagnetic system where permanent magnets are directly mounted on the stator. This substitution eliminates the mechanical inertia associated with rotor cores, enabling faster response speeds while maintaining torque output through direct electromagnetic interaction.
2Force
If a rotor core structure is used in tubular motors, then the motor can generate sufficient torque, but vibration increases and service life decreases
Solution Approach 1:
The patent extracts and removes the rotor core component that causes vibration and reduces service life. By eliminating this problematic element entirely and using a coreless structure with permanent magnets on the stator, the system achieves reduced vibration and improved reliability while maintaining necessary torque output.
3Stability of the object's composition
If magnetic shoes (permanent magnets) are fixed on the housing with certain thickness, then the motor structure is stable, but the outer diameter of the motor rotor is limited and output torque is reduced
Solution Approach 1:
The patent repositions the permanent magnets from the rotor (radial dimension) to the stator (axial dimension), allowing the magnets to be arranged in an array along the axial direction. This dimensional change enables increased torque output without increasing the motor's outer diameter, as the magnetic field generation occurs in a different spatial configuration.
Solution Approach 2:
The patent merges the functions of the rotor and stator by mounting permanent magnets directly on the stator housing. This integration eliminates the need for a separate rotor structure, allowing the magnetic field generation to occur directly at the stator, thereby maximizing torque output within the given outer diameter constraints.
4Speed
If speed reducers are added to tubular motors, then the rotating speed of the output shaft can be reduced, but the structure becomes less compact and transmission stability deteriorates
Solution Approach 1:
The patent merges the motor and speed reducer into a single integrated unit where the planetary gear mechanism is built-in. This integration eliminates the need for separate external speed reducers, maintaining structural compactness while providing the necessary speed reduction. The built-in design also improves transmission stability by reducing the number of external connection points and alignment requirements.
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 motor design reduces heat generation, energy consumption, and vibration, enhances torque output, and improves transmission stability and braking performance, leading to increased service life and efficiency.
Implementation Method 1
the motor main body is a coreless motor
Implementation Method 2
a brake mechanism with a torsion spring
Data Source
AI summary
A tubular motor assembly using a coreless motor structure is provided includes: a steel tube body and a coreless motor, wherein one end of a motor main body is inserted at one end of a battery circuit board housing; a control circuit board and/or a power supply battery is provided within the battery circuit board housing; the other end of the motor main body is connected to a primary gear ring; a motor shaft of the motor main body is connected to a primary planetary gear assembly; the other end of the primary gear assembly is connected to a secondary/tertiary gear ring through a brake outer sleeve; the primary planetary gear assembly is connected to a secondary planetary gear assembly through a brake structure; and a tertiary planetary gear assembly is connected to an output shaft.