External Rotor Motor Roller System Torque Transmission
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Solution Overview
Problem
Existing roller systems face inefficiencies and stress issues due to cantilevered motor couplings and limitations in torque delivery, which affect their robustness and scalability for various applications.
Innovation Solution
A roller system design featuring a gearless external rotor motor with a stator and external rotor positioned radially outward, coupled with a transmission system that avoids cantilevering forces by using bearings to support the rotor and transmit torque to rollers through a non-cantilevered mechanism, allowing for higher torque and easier maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional cantilevered motor coupling is used, then the motor can be directly coupled to the roller, but the motor experiences high stress and reduced reliability
Solution Approach 1:
A non-cantilevered transmission coupling mechanism is introduced as an intermediary between the motor and roller. This coupling includes a transmission shaft, bearings, and a transmission belt that transfer torque from the motor shaft to the roller shaft without creating cantilevered loads on the motor, thereby reducing motor stress while maintaining reliable power transmission
Solution Approach 2:
The power transmission path is segmented into distinct components: motor shaft, transmission coupling mechanism (with shaft and bearings), transmission belt, and roller shaft. This segmentation allows the motor to be isolated from direct mechanical stress while still delivering torque effectively through the distributed transmission system
2Force
If a gearless external rotor motor is used, then torque delivery is improved, but the motor positioning and support complexity increases
Solution Approach 1:
The motor is positioned in three-dimensional space above the roller plane rather than directly coupled at the same level. The transmission coupling mechanism bridges this spatial separation, allowing the external rotor motor to deliver high torque while its support structure is distributed across multiple mounting points on the frame, reducing structural complexity
Solution Approach 2:
The transmission coupling mechanism serves multiple functions: it transmits torque from the motor to the roller, supports the motor weight through bearings, and positions the motor optimally for high torque delivery. This multi-functionality reduces the need for separate support structures, simplifying the overall system despite the motor's elevated position
3Device complexity
If the motor is positioned close to the rollers for direct coupling, then the system structure is simplified, but torque transmission efficiency decreases
Solution Approach 1:
A transmission belt acts as an intermediary power transmission element between the motor shaft and roller shaft. This belt-driven connection allows for efficient torque transmission over a greater distance, maintaining high power transmission efficiency while enabling the motor to be positioned optimally for torque delivery without requiring direct mechanical coupling
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 robust, scalable, and efficient roller system capable of handling high torque applications while minimizing stress on the motor and extending its lifespan, with improved ease of maintenance and adaptability to different configurations.
Implementation Method 1
an external rotor motor ('motor') having a motor shaft. The plurality of roller shafts forms a roller shaft plane, and the motor shaft is spaced from the roller shaft plane. As an external rotor motor, the motor has a stator and an external rotor radially outward of the stator
Implementation Method 2
The transmission coupling and external rotor are configured so that rotation of the external rotor causes the at least one roller to rotate in response to a torque received through the transmission coupling
Data Source
AI summary
A roller system has a frame, a plurality of rollers (supported by the frame) forming a roller plane, and an external rotor motor (“motor”) spaced from the roller plane. As an external rotor motor, the motor has a stator and an external rotor radially outward of the stator to substantially circumscribe the stator. To kinetically couple the motor with the rollers, the system also has a transmission coupling coupled with the external rotor and at least one of the rollers. The transmission coupling and external rotor are configured so that rotation of the external rotor causes the at least one roller to rotate in response to a torque received through the transmission coupling.