Drive Unit Rotor Coupling for Reliable Torque Transmission
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conveyor roller systems face issues with unreliable power transmission and axial bearing problems due to frictional connections and fixed axial positions, leading to inefficiencies and operational safety concerns, especially under varying environmental conditions.
Innovation Solution
A drive unit with a non-rotatable connection between the rotor element and a coupling element, featuring connecting projections for secure power transmission to a support roller, ensuring reliable and loss-free torque transfer through a form-fitting connection, which is robust and safe even with frequent starts and stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a frictional connection is used for power transmission in the pressing unit, then the structure is simple and easy to assemble, but the power transmission becomes unreliable over time due to changing frictional connection
Solution Approach 1:
The pressing unit is divided into two independently adjustable pressing elements instead of a single fixed pressing unit. Each pressing element can be adjusted separately to optimize the frictional connection, allowing maintenance of reliable power transmission while preserving the simple friction-based design. The segmentation enables independent adjustment of each pressing element's position and pressure.
Solution Approach 2:
The pressing elements are made adjustable rather than fixed, allowing dynamic adaptation of the frictional connection over time. The axial positions of the pressing elements can be modified to compensate for wear and changing friction conditions, ensuring continuous reliable power transmission while maintaining the simplicity of the frictional connection design.
2Device complexity
If the pressing unit has a fixed axial position, then the structure is simplified, but the bearing of the transmission output shaft is unfavorably affected due to the fixed position acting as an additional fixed bearing
Solution Approach 1:
The pressing elements are designed with adjustable axial positions rather than being fixed. This allows the pressing elements to adapt to different operating conditions and wear states, preventing the fixed bearing effect from degrading output shaft bearing performance while maintaining relatively simple structure through the use of basic adjustment mechanisms.
3Reliability
If a planetary gear with hexagonal output shaft is used for torque transmission, then the torque transmission is reliable and torque-proof, but the device complexity increases with the clutch unit and additional components
Solution Approach 1:
The planetary gear mechanism is extracted and replaced with a direct connection between the electric motor's rotor and the output shaft. The hexagonal cross-section connection is retained for reliable torque transmission, but the complex planetary gear and clutch unit are eliminated, significantly reducing device complexity while maintaining torque-proof transmission reliability.
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 provides a reliable, efficient, and compact power transmission system with minimal losses, enhanced operational safety, and reduced susceptibility to faults, suitable for diverse environmental conditions.
Implementation Method 1
an electric rotary drive (3), which has a stator element (4), in particular for mounting on a frame element (10, 21), and a rotor element (5) for providing a torque
Implementation Method 2
The rotor element (5) has connecting projections (17) which abut laterally against connecting projections (16) of the coupling element (11) for producing a non-rotatable connection
Data Source
Figure 1~3
Figure 4~9
Figure 10~11
AI summary
Drive unit (1) for a transport roller (2), with an electric rotary drive (3) comprising a stator element (4) in particular for mounting on a frame element and a rotor element (5) for transmitting a torque, wherein the rotor element (5) of the rotary drive (3) is connected via a rotationally fixed connection to a coupling element (11) which has at least a recess (12) on a cylindrical surface for receiving a power transmission element, in particular a belt element, for transmitting power to a support roller, transport roller and transport device.