Eccentric Rotor Motor Torque via Magnetic Rolling
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Solution Overview
Problem
Traditional electric motors that require high torque are often too heavy due to their size or the need for heavy gearboxes, making them unsuitable for lightweight applications such as robotics, material handling, and automotive systems.
Innovation Solution
The development of an eccentric high torque electric motor where the rotor is oriented eccentrically relative to the stator, allowing for a rolling contact that maintains a close proximity without direct contact, utilizing magnetic forces to generate torque without increasing the size or weight of the motor, and featuring a crankshaft with bearings for smooth rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional electric motors are made larger or incorporate heavy gear boxes to produce higher torques, then torque output is improved, but weight increases making them unsuitable for lightweight applications
Solution Approach 1:
The rotor is positioned eccentrically relative to the stator, creating an asymmetric configuration where the rotor axis is offset from the stator axis. This asymmetry enables the rotor to maintain rolling contact with the stator while rotating, generating high torque through the eccentric motion without requiring increased motor size or heavy gearboxes
Solution Approach 2:
The patent replaces the traditional mechanical gearbox system with an electromagnetic rolling contact system. The electromagnetic coils create magnetic fields that attract the rotor, causing it to roll along the stator surface. This substitution eliminates the need for heavy mechanical gearboxes while maintaining high torque output capability
2Force
If the rotor is positioned eccentrically to maintain rolling contact with the stator, then high torque is generated, but the air gap consistency is compromised
Solution Approach 1:
The rotor axis travels in a circular path around the stator axis during rotation, creating a dynamic air gap that varies continuously. This dynamic configuration is controlled through sequential excitation of electromagnetic coils, which guide the rotor's eccentric motion to maintain optimal rolling contact while generating torque
3Ease of operation
If successive coils are excited to cause the rotor to roll along the stator, then electromagnetic control is improved, but system complexity increases
Solution Approach 1:
The electromagnetic coils are excited in a sequential, periodic manner to create the rotating magnetic field that drives the rotor. Each coil or coil set is activated in succession as the rotor progresses around the stator, creating a continuous rolling motion through rhythmic electromagnetic attraction cycles
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
This design achieves high torque output while maintaining a lightweight structure, suitable for various applications including robotic systems, automated vehicles, and material handling, without the need for heavy gearboxes.
Implementation Method 1
The stator in one example has sets of electromagnetic coils to produce a magnetic field that attracts the rotor. This magnetic field acts axially to the coils. Successive coils are excited causing the rotor to roll along the stator.
Implementation Method 2
In one variation, the rotor is made of pairs of permanent magnets and/or ferritic materials with high magnetic permeability.
Data Source
AI summary
A drive system for a high torque mechanical load includes a power supply, a controller, and a high torque electric motor. The electric motor includes a rotor that is oriented eccentrically relative to a stator. In one form, the electric motor has a crankshaft that transmit the torque to the mechanical load. In other variations, the electric motor includes at least two electric motor lobes with opposite stroke positions to provide a smoother output at higher speeds. During operation, the rotor is magnetically attracted to the energized electromagnet. With the rotor attracted to the electromagnet in the stator, the rotor contacts or comes in close proximity to the stator at a contact area. The close proximity between the rotor and stator at the contact area allows very large magnetic forces to be utilized to produce torque without increasing the size or weight of the electric motor.