Gear Reducer Motor Assembly with Internal Brake Nesting
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Solution Overview
Problem
Existing electric drive systems for large boom lifts are inefficient due to high power demands from hydraulic systems, which are not well-suited for peak power requirements, leading to inefficiencies and increased emissions, and lack the power density and environmental protection needed for outdoor use.
Innovation Solution
A compact electric wheel drive assembly featuring a high-speed electric motor, internal brake, and three-stage gear reducer, with the brake nested within the motor windings, providing a high power density and environmental protection, allowing for a hybrid electric system that reduces emissions and improves efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a hydraulic system is used to drive wheels on large boom lifts, then peak power and torque requirements are met, but the system becomes inefficient and produces high emissions due to constant peak power demand from the internal combustion engine
Solution Approach 1:
The patent replaces the hydraulic mechanical system with an electric motor system. The electric motor directly drives the planetary gearbox and wheel hub, eliminating the need for hydraulic fluid transmission and the internal combustion engine that drives it, thereby improving energy efficiency and reducing emissions while maintaining the required power and torque output.
Solution Approach 2:
The patent changes the operating parameters of the drive system by using an electric motor that can efficiently deliver variable power and torque across different operating conditions, rather than the hydraulic system that requires constant peak power from the engine. This allows the system to operate efficiently at partial load conditions while still meeting peak requirements.
2Volume of moving object
If the brake is nested within the motor windings, then the assembly achieves high power density and compactness, but the brake structure becomes more complex
Solution Approach 1:
The brake assembly is nested within the motor windings, utilizing the space between the motor shaft and the outer casing. The brake drum, friction lining, and actuating mechanism are arranged concentrically within the motor structure, allowing the brake to be integrated into the motor housing without increasing the overall external dimensions of the assembly.
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 enables a more efficient and environmentally friendly electric drive system for large boom lifts, reducing emissions and improving power density, enabling operation in outdoor environments while maintaining compactness and reliability.
Implementation Method 1
The brake is electrically actuated which disengages the pressure plate from the friction plate or disc to permit rotation of the motor shaft and transmission of energy to the gear reducer
Implementation Method 2
The brake is operable against a spring biasing said brake into engagement with a friction plate
Data Source
AI summary
A compact gear reducer electric motor assembly with an internal brake disclosed and claimed wherein a high speed electric motor is interconnected with a gear reducer having substantial gear reduction. The assembly includes a spindle, a brake mounted substantially within said high speed electric motor and operable against a spring biasing said brake into engagement with ground. The brake is electrically actuated to permit transmission of energy to the gear reducer. The gear reducer includes an input, intermediate and output planetary stages. The input and intermediate stages residing within the spindle, and, the output planetary stage drives an output ring gear. Releasing means for releasing the output ring gear from the brake allowing rotation thereof.