Integrated Actuator Torque-to-Weight Ratio via Merged Motor Gear
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing actuators, such as geared motors, have a high number of parts due to independent manufacturing of motors and gears, leading to increased weight and difficulty in reducing the total number of components.
Innovation Solution
An actuator design that integrates a stator with teeth on its outer peripheral surface, a rotor with teeth meshing with the stator's teeth, and a second gear coupled to an output shaft, where the stator has an electromagnet and the rotor has a magnet, allowing magnetic pole movement to rotate the gear system efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electric motor and speed reducer are made independently, then each component can be optimized separately, but the total number of parts increases and weight increases
Solution Approach 1:
The patent merges the motor and speed reducer into a single integrated actuator unit. The motor's rotor is directly coupled with the speed reducer's input shaft, eliminating the need for separate mounting flanges, fasteners, and alignment mechanisms. This integration reduces the total part count while maintaining the ability to optimize each subsystem independently through modular design within the unified structure.
2Power
If more parts are used to achieve high output, then performance can be improved, but weight increases
Solution Approach 1:
The integration of motor and speed reducer eliminates the weight of intermediate coupling components, mounting structures, and fasteners. The shared housing and direct coupling reduce material usage while maintaining the high output capability through optimized gear ratios and motor selection within the integrated unit.
Solution Approach 2:
The speed reducer is nested within the motor housing, with the gear train positioned inside the motor's structural envelope. This nesting arrangement eliminates redundant housing walls and allows the output shaft to pass through or extend from the motor housing, reducing overall structure weight while maintaining high output torque through the gear reduction mechanism.
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
This design achieves high output with a smaller number of parts, reducing weight and manufacturing costs while increasing the torque-to-weight ratio and enhancing the robustness of the gear system.
Implementation Method 1
the stator has an electromagnet, the rotor has a magnet
Implementation Method 2
a magnetic pole of the electromagnet corresponding to a position of the rotor moves along a circumferential direction of the stator
Implementation Method 3
a rotor that rotates around a central axis of the stator while teeth arranged on an outer peripheral surface mesh with the teeth arranged on the outer peripheral surface of the stator
Implementation Method 4
a second gear that rotates while meshing with a first gear coupled to the rotor coaxially with a central axis of the rotor and is coupled to an output shaft
Data Source
AI summary
An actuator capable of achieving high output with a smaller number of parts is proposed. An actuator including a stator that has teeth arranged on an outer peripheral surface, a rotor that rotates around a central axis of the stator while teeth arranged on an outer peripheral surface mesh with the teeth arranged on the outer peripheral surface of the stator, and a second gear that rotates while meshing with a first gear coupled to the rotor coaxially with a central axis of the rotor and is coupled to an output shaft, in which the stator has an electromagnet, the rotor has a magnet, and a magnetic pole of the electromagnet corresponding to a position of the rotor moves along a circumferential direction of the stator.