Brushless Motor Drive Device with Elliptical Reduction Gear
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Solution Overview
Problem
Existing drive devices with electric motors and reduction gears in motor vehicles face challenges in optimizing their placement and reducing size, weight, and noise, especially in confined spaces like vehicle seats and doors.
Innovation Solution
A drive device featuring a brushless motor with an elliptical reduction gear and a control unit, optimized for compact installation, using a deformable elliptical ring and a supporting ring, arranged coaxially or in a flat configuration with a belt connection, and equipped with a control unit for smooth operation and safety shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a DC motor is used in the drive device, then the motor can provide sufficient torque, but the dimensions and weight of the drive device increase
Solution Approach 1:
The patent combines the motor and reduction gear into a single integrated drive device unit. The motor is positioned directly adjacent to the elliptical reduction gear, eliminating the need for separate mounting brackets and connection mechanisms. This merging reduces the overall weight and volume while maintaining the necessary torque transmission functionality.
Solution Approach 2:
The patent employs an elliptical reduction gear instead of a conventional circular gear. The elliptical shape allows for a more compact arrangement of the drive mechanism, reducing the radial space requirements and enabling a more favorable weight-to-torque ratio. The curved elliptical path of the reduction gear optimizes the mechanical advantage while minimizing the overall dimensions of the drive device.
2Force
If a DC motor is used in the drive device, then the motor can provide sufficient torque, but the dimensions of the drive device increase
Solution Approach 1:
The motor and reduction gear are merged into a single compact unit, with the motor positioned directly adjacent to the elliptical reduction gear. This integration eliminates intermediate connection components and reduces the overall volume of the drive device while maintaining full torque transmission capability.
Solution Approach 2:
The elliptical reduction gear utilizes its curved geometry to achieve a more compact configuration compared to conventional circular gears. The elliptical shape allows for optimized space utilization, reducing the radial and axial dimensions of the drive device while preserving the necessary mechanical advantage for torque multiplication.
3Ease of manufacture
If the motor and reduction gear are arranged in a conventional configuration, then the components are easy to manufacture, but the placement options are restricted
Solution Approach 1:
The elliptical reduction gear's unique curved geometry provides multiple orientation options for mounting the drive device. The elliptical shape can be oriented with its major axis horizontal, vertical, or at intermediate angles, allowing the drive device to be installed in various spatial configurations within the vehicle interior while maintaining manufacturing simplicity.
Solution Approach 2:
The asymmetric elliptical shape of the reduction gear breaks the conventional circular symmetry, creating a compact form factor that can be adapted to different mounting locations. This asymmetric geometry allows the drive device to fit into confined spaces with varying clearance requirements, enhancing placement versatility without complicating the manufacturing process.
4Volume of moving object
If the dimensions of the drive device are reduced, then the placement options are optimized, but the motor size constraints increase
Solution Approach 1:
The elliptical reduction gear's curved geometry enables a compact arrangement that reduces the overall volume of the drive device. The elliptical shape optimizes the space utilization, allowing the motor to be positioned in confined spaces within the vehicle interior while maintaining adequate clearance and access for installation and maintenance.
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 allows for reduced dimensions, weight, and noise, enabling efficient installation in confined spaces while ensuring smooth operation and safety, with a standard reduction rate and optimal rotational speed.
Implementation Method 1
an elliptical reduction gear interposed between the brushless motor and the output member, said elliptical reduction gear comprising a drive member and a deformable elliptical ring deformed by the drive member during its rotation, against a supporting ring
Data Source
AI summary
Drive device (1) with electric motor and reduction gear driving an output unit (8) in a motor vehicle, comprising a brushless motor (2) having a rotor turning about a rotor axis (Y2) parallel to a main axis (Y), an elliptical reduction gear (3) interposed between the brushless motor (2) and the output unit (8), said elliptical reduction gear comprising an elliptical gear and a deformable flange, deformed by the elliptical gear when it rotates, and a control unit (4) arranged in the immediate proximity of the brushless motor (2) for controlling said brushless motor. Seat frame comprising such a device.