Gear Motor Intermediate Flange Design for Compact Variance
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Solution Overview
Problem
Existing geared motor designs face challenges in achieving a simpler, more cost-effective, and compact manufacturing process while allowing for a high degree of variance with fewer components.
Innovation Solution
The geared motor design incorporates a housing with an intermediate flange and end shield, where the intermediate flange supports two bearings for an intermediate shaft, enabling easy variance in gear stages and preassembly, with a ring-like outer structure for minimal mass increase and secure bearing retention using retaining rings, and features an uninterrupted annular groove for sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an intermediate stage is added to increase gear variance, then adaptability is improved, but device complexity increases
Solution Approach 1:
The intermediate flange combines multiple functions: it serves as a mounting structure for intermediate shaft bearings, provides sealing surfaces with annular grooves for O-rings, and acts as a structural connector between housing parts. This merging of functions into a single component reduces the total number of parts while enabling gear stage variance.
Solution Approach 2:
The intermediate flange is designed as a universal component that can accommodate different bearing arrangements and seal configurations. Its multi-functional design allows it to support intermediate stages when needed while maintaining a compact structure, enabling the same basic design to serve multiple gear stage configurations.
2Reliability
If traditional sealing methods with multiple segments are used, then sealing reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing function is extracted from the structural components and implemented through dedicated annular grooves in the intermediate flange. These grooves hold O-rings that provide sealing between the intermediate flange and adjacent housing parts, separating the sealing function from the load-bearing structure.
Solution Approach 2:
O-rings (flexible sealing elements) are used instead of rigid segmented seals. The O-rings are installed in uninterrupted annular grooves cut into the intermediate flange, providing effective sealing while simplifying the manufacturing process compared to traditional multi-segment seal designs.
3Volume of moving object
If a compact design is pursued, then volume is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The intermediate flange is designed with an axial width that is less than the total axial width of the intermediate stage it supports. This allows the holding structure for bearings to project axially beyond the flange face, effectively nesting the bearing support function within the compact flange structure while maintaining adequate space for all components.
4Reliability
If conventional bearing retention methods are used, then reliability is improved, but mass increases
Solution Approach 1:
The retaining rings for axial bearing retention are integrated directly into the holding structure of the intermediate flange. This merging of retention functionality into the existing bearing support structure eliminates the need for separate retention mechanisms, reducing mass while maintaining reliable bearing retention.
Data Source
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AI summary
The invention relates to a gear motor and a production method for a gear motor, having a selectable gear speed number, and having a housing, comprising at least one housing part, an intermediate flange, and a bearing plate, wherein the housing part, the intermediate flange, and the bearing plate are interconnected. The intermediate flange is arranged between the housing part and the bearing plate. The bearing plate accommodates a bearing for supporting the rotor shaft of the motor, wherein the intermediate flange accommodates two bearings in an intermediate shaft.