Direct Drive Rail Assembly With Nested End-Cover Mounting
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Solution Overview
Problem
Existing direct drive transmission systems suffer from loose fits between guide rails and end covers, leading to poor assembly, inadequate size, and low bearing capacity.
Innovation Solution
A direct drive transmission system design featuring recessed mounting grooves in end covers and guide rails, allowing for a tight fit and compact assembly, with drive units and position feedback devices for precise motion control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the guide rail and end cover are arranged with a mounting distance or flush arrangement, then the assembly is easier to manufacture, but the fit is not tight enough, resulting in poor assembly effect and low bearing capacity
Solution Approach 1:
The guide rail ends are inserted into mounting grooves formed in the end covers, creating a nested structure where the guide rail is partially contained within the end cover. This nesting arrangement achieves a tight fit between the guide rail and end cover, improving manufacturing precision and bearing capacity while maintaining ease of assembly through the straightforward insertion process
Solution Approach 2:
The mounting groove extends in the thickness direction of the end cover, utilizing the third dimension (depth) to create the tight fit. Instead of relying solely on lateral positioning, the groove provides vertical containment that secures the guide rail firmly, achieving precise fitting without increasing lateral dimensions or assembly complexity
2Ease of operation
If the guide rail and end cover are arranged with a mounting distance, then the linear motion of movers is facilitated, but the size of the direct drive motor increases
Solution Approach 1:
The guide rail ends are nested within the end covers through the mounting groove structure, eliminating the need for additional mounting distance between the guide rail and end cover. This nesting arrangement allows the guide rail to extend directly to the end cover face, reducing the overall length dimensions of the motor while maintaining smooth linear motion of the movers along the guide rail
Solution Approach 2:
The mounting groove utilizes the thickness direction (z-axis) of the end cover to accommodate the guide rail ends, rather than requiring additional length in the motion direction (x-axis). This dimensional repositioning allows the guide rail to maintain its full length for smooth mover motion while the end cover absorbs the mounting interface in its thickness, thereby reducing the overall motor length
3Length of moving object
If the guide rail and end cover are arranged flush, then the motor size is reduced, but the fit is not tight enough, resulting in low bearing capacity
Solution Approach 1:
The guide rail ends are inserted into and contained by the mounting grooves in the end covers, creating a nested structure that provides both compact dimensions and strong mechanical support. This nesting arrangement ensures the guide rail is firmly held by the end cover, significantly improving bearing capacity to support the movers while maintaining reduced motor size through the flush arrangement
Solution Approach 2:
The mounting groove utilizes the thickness direction of the end cover to provide bearing support for the guide rail ends. By transferring the support function from a lateral interface to a vertical groove structure, the end cover achieves strong bearing capacity in a compact configuration, supporting the guide rail firmly without increasing the motor's external dimensions
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 system achieves a more compact motor design with improved assembly and bearing capacity, facilitated by the tight fit of guide rails and end covers, and enhanced positioning accuracy through feedback devices.
Implementation Method 1
the first drive unit and the second drive unit generating mutual thrust to drive the slide to drive the second guide rail to move linearly along the first guide rail of the base
Data Source
AI summary
The disclosure provides a direct drive transmission system including a mover unit and a stator unit driving the mover unit to move. The stator unit includes a stator assembly, two first end covers, and two first guide rails. A side of the first end cover close to the first guide rail is recessed inwardly to form a first mounting groove, and two ends of the first guide rail are respectively inserted into the first mounting groove. The mover unit includes a mover assembly, two second end covers, and two second guide rails. A side of the second end cover close to the second guide rail is recessed inwardly to form a second mounting groove, two ends of the second guide rail are respectively inserted into the second mounting groove. The stator assembly drives the mover assembly to cause the second guide rail to move on the first guide rail.