Gear Motor Rotor Shaft Support via Coupling Sleeve
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Solution Overview
Problem
Existing geared motors face challenges in manufacturing ease, compactness, and power loss due to the need for multiple bearings, with the rotor shaft not being fully supported during assembly, leading to potential wear and inefficiencies.
Innovation Solution
A geared motor design featuring a stator housing with a rotor shaft supported by a first bearing and a second bearing via a coupling sleeve, where the sun gear is rotationally fixed to the coupling sleeve, allowing for direct mounting and reduced bearing requirements, with a temporary plain bearing bushing for assembly support and lubrication to prevent wear and power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple bearings are used to fully support the rotor shaft, then the rotor shaft support stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the functions of multiple bearings into a single bearing arrangement. The first bearing is integrated into the stator housing to support the rotor shaft, while the second bearing is incorporated into the adapter ring that connects the gearbox to the motor. This merging of support functions reduces the total number of bearings needed while maintaining adequate rotor shaft stability during operation.
Solution Approach 2:
The patent employs a temporary plain bearing bushing that is installed on the rotor shaft before final assembly. This preliminary bearing arrangement provides sufficient support during assembly and functional testing, allowing the motor to be tested before complete installation. The temporary bushing is later removed or worn down during operation, at which point the permanent first and second bearings provide full support.
2Ease of manufacture
If a temporary plain bearing bushing is used during assembly, then the ease of assembly and functional testing is improved, but power loss and wear may occur during operation
Solution Approach 1:
The plain bearing bushing serves as a temporary preliminary support during assembly and testing phases. It allows the rotor shaft to be properly positioned and the motor to be functionally tested before final installation. The bushing is designed to be worn down or removed during operation, at which point the permanent ball bearings take over to eliminate power loss and wear issues.
Solution Approach 2:
The plain bearing bushing is designed as a temporary, consumable component that serves its purpose during assembly and testing, then gradually wears down during operation. This disposable approach allows for easier assembly and testing while accepting that the temporary bushing will eventually be replaced or worn away, at which point the permanent bearings provide efficient operation without power loss.
3Device complexity
If fewer bearings are used, then the device complexity is reduced, but the rotor shaft cannot be fully supported during assembly
Solution Approach 1:
The plain bearing bushing is installed as a preliminary measure to provide adequate rotor shaft support during assembly and testing. This temporary bushing ensures the rotor shaft is properly supported before the permanent bearing arrangement is fully installed. Once assembly and testing are complete, the bushing is worn down or removed, and the permanent first and second bearings provide full support during operation.
Solution Approach 2:
The plain bearing bushing acts as an intermediary component that bridges the gap between assembly requirements and final operation. During assembly, the bushing provides the necessary support that would otherwise require the permanent bearings to be pre-installed. The bushing mediates between the need for simple assembly and the need for reliable rotor shaft support, allowing assembly to proceed with fewer permanent components in place.
4Reliability
If the rotor shaft is allowed to expand axially due to thermal expansion, then the reliability is improved, but noise and wear may occur
Solution Approach 1:
The patent allows the rotor shaft to expand axially in response to thermal changes by providing clearance between the rotor shaft and the coupling sleeve. This parameter change in the clearance dimension accommodates thermal expansion without creating harmful contact forces. The coupling sleeve is positioned such that it does not constrain the rotor shaft during thermal expansion, preventing noise and wear that would result from rigid constraint.
Solution Approach 2:
The coupling sleeve acts as an intermediary component between the rotor shaft and the sun gear. It transmits rotational motion from the rotor shaft to the sun gear while allowing axial movement of the rotor shaft due to thermal expansion. The coupling sleeve mediates between the need for rigid rotational coupling and the need for axial freedom, enabling thermal expansion without creating noise or wear through proper design of the coupling interface.
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 design enables a compact, cost-effective, and reliable geared motor with reduced power loss, allowing for functional testing before full assembly and stable support during operation, while minimizing noise and wear through lubrication and sealing mechanisms.
Implementation Method 1
the electric motor has a stator housing, a rotor shaft and a first bearing, in particular rolling bearings, in particular ball bearings, for supporting the rotor shaft
Implementation Method 2
an inner ring of a second bearing, in particular rolling bearings, in particular ball bearings, is fitted onto the coupling sleeve
Implementation Method 3
The space between the sun gear and the rotor shaft contains lubricant, particularly grease
Data Source
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AI summary
The invention relates to a gear motor comprising an electric motor and a gearbox, wherein the electric motor has a stator housing (1), a rotor shaft (16) and a first bearing for mounting the rotor shaft, wherein a coupling sleeve (11) is fitted onto the rotor shaft (16) and connected to the rotor shaft (16) for conjoint rotation, wherein an inner ring of a second bearing, in particular a roller bearing, in particular a ball bearing, is fitted onto the coupling sleeve (11) and the outer ring of the second bearing is accommodated in an adapter ring which is connected to a housing part (6) of the gearbox for conjoint rotation, wherein the adapter ring (4) is connected, on the side thereof facing away from the housing part (6), to an annular circular flange (3) which is connected, on the side thereof facing away from the adapter ring (4), to a circular flange (2) connected to the stator housing (1).