Integrated Drive Gear Motor Assembly Without Spline Connections
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Solution Overview
Problem
Existing motor designs with spline connections are bulky, heavy, imprecise, and require frequent maintenance due to inadequate spline formation, which is undesirable in environments requiring high precision and space efficiency.
Innovation Solution
An integrated drive gear motor assembly with a motor output shaft and drive gear formed as a unitary piece, utilizing ball bearings for support and rotation, eliminating the need for auxiliary connections and reducing the overall size and weight while maintaining torque capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If spline connections are used to connect the shaft and drive gear, then the connection provides torque transmission capability, but the outer diameter of the shaft increases and the overall size of the motor increases
Solution Approach 1:
The drive gear is integrally formed with the motor output shaft as a unitary one-piece structure, eliminating the need for separate spline connections. This merging of components transmits torque directly through the integrated structure while reducing the outer diameter and overall motor size compared to traditional spline-based connections.
2Force
If spline connections are used to connect the shaft and drive gear, then the connection provides torque transmission capability, but the weight of the motor increases
Solution Approach 1:
The integral formation of the drive gear and motor output shaft eliminates redundant material and connection structures. By combining these components into a single piece, the design reduces overall weight while maintaining sufficient torque capacity through optimized structural design.
3Ease of manufacture
If spline connections are used to connect the shaft and drive gear, then the connection can be formed with standard manufacturing processes, but the connection precision is inadequate and requires frequent maintenance
Solution Approach 1:
The unitary construction of the motor output shaft and drive gear eliminates interface errors and misalignment issues inherent in separate component connections. This integral design ensures precise concentricity and rotational accuracy without requiring high-precision spline machining, thereby improving reliability and reducing maintenance needs.
4Reliability
If the splines are made large enough to ensure secure connection, then the connection reliability improves, but the space required increases and the motor cannot fit in available space
Solution Approach 1:
The integrated design eliminates the need for large-dimensional spline connections by transmitting torque through the continuous structure of the unitary component. This approach achieves secure and reliable torque transmission without increasing the motor's outer diameter, allowing the motor to fit within compact available spaces.
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 achieves a compact, lightweight, and precise connection that operates smoothly with reduced noise and maintains sufficient torque, addressing the limitations of traditional spline connections.
Implementation Method 1
utilizing ball bearings for support and rotation
Data Source
AI summary
An integrated active gear motor assembly may have a housing with a stator and a rotor located within the housing. The assembly may also have a motor output shaft located within the stator with a gear portion of the motor output shaft extending out of the housing. A drive gear may be connected to the gear portion of the shaft. The drive gear may be integrally formed, unitary and one-piece with the motor output shaft to rotate with the motor output shaft.