Gear Motor Assembly Rotor Balance via Bushing Positioning
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Solution Overview
Problem
The existing gear motor assemblies face challenges in maintaining balance performance due to the assembly of the worm, which affects the rotor balance, and the need to prevent shaft bending under counterforces from the worm gear during operation.
Innovation Solution
A gear motor assembly design that includes a bushing slidably mounted on the shaft between the commutator and the worm, with a sleeve fixed to the shaft to ensure the bushing is properly positioned and fixed in the gearbox casing, allowing for balanced rotor assembly and preventing shaft bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the worm is assembled to the shaft after the shaft extends through the end cap, then the worm can be properly mounted, but the rotor balance is adversely affected
Solution Approach 1:
The rotor is balanced before the worm is assembled to it. This preliminary balancing action ensures that the rotor achieves its optimal balance state before the worm, which would adversely affect balance, is mounted onto the shaft.
Solution Approach 2:
The end cap is eliminated from the design. By removing the end cap, the patent allows the shaft to extend directly into the gearbox casing, enabling the worm to be mounted on the shaft before final assembly without compromising rotor balance.
2Ease of manufacture
If the end cap is eliminated to allow post-assembly of the worm, then worm mounting becomes easier, but the bearing mounting position becomes problematic
Solution Approach 1:
The gearbox casing is designed to serve multiple functions: it receives the shaft with the mounted worm, provides mounting positions for the bearing, and supports the overall structure. This multi-functional design eliminates the need for a separate end cap while maintaining all necessary support functions.
Solution Approach 2:
A bushing is introduced as an intermediary component between the shaft and the gearbox casing. The bushing is slidably mounted on the shaft and fixed in the casing, providing the necessary bearing support function that would otherwise require the end cap.
3Reliability
If the bushing is slidably mounted on the shaft and fixed in the casing, then the shaft bending is prevented, but the assembly complexity increases
Solution Approach 1:
The bushing is designed to be self-positioning through its sliding mounting on the shaft. During assembly, the bushing slides onto the shaft and is subsequently fixed in the casing, automatically achieving proper positioning without requiring additional alignment procedures or complex assembly mechanisms.
Data Source
AI summary
A gear motor assembly includes a motor and a gearbox connected together. The motor includes a stator and a rotor. The stator has a housing, magnets attached to the housing, and brushes. The rotor includes a shaft with a rotor core, a commutator, a sleeve, a bushing and a worm mounted thereon. The bushing is slidably located between the commutator and worm. The sleeve is located between the commutator and the bushing. The rotor is balanced with the worm fix to the shaft. The gearbox includes a casing having an opening, and a worm gear received in the casing. The brushes of the motor are mounted in the casing. The shaft has a first end that extends into the gearbox. The bushing is fixed in the casing via a bushing seat.