Integrated Gear Motor Brake Monobloc Design
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Solution Overview
Problem
Current gear-motor systems for electric-traction vehicles face issues such as unnecessary encumbrance, noise, instability, high costs, and limited versatility due to the need for separate motor and transmission components, as well as complex alignment and maintenance challenges.
Innovation Solution
An integrated gear-motor with a built-in brake forms a compact monobloc system where the motor casing is part of the transmission, allowing easy access and adaptability, with the motor shaft serving as input gear, driving shaft, and braking connection, enabling various braking systems without altering the structure, and utilizing oil for cooling and recirculation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate motor and transmission components are used, then the system can be assembled from standard parts, but the system becomes encumbered and requires complex alignment causing noise and instability
Solution Approach 1:
The patent integrates the motor directly into the transmission housing, creating a monobloc structure where the motor casing forms an integral part of the transmission assembly. This eliminates separate alignment requirements between motor and transmission, removing the source of noise and instability while maintaining ease of manufacture through the unified design.
2Adaptability or versatility
If separate motor and transmission components are used, then component replacement is flexible, but the system requires support means for all rotating elements increasing complexity
Solution Approach 1:
By merging the motor and transmission into a single integrated unit, the patent eliminates the need for separate support means for rotating elements. The unified structure shares common support infrastructure, reducing overall device complexity while maintaining adaptability through modular design elements that allow component replacement.
3Adaptability or versatility
If external motor is installed separately, then motor selection is flexible, but alignment difficulties generate noise and system instability
Solution Approach 1:
The integration of motor and transmission eliminates misalignment issues entirely by design, as the motor shaft is directly coupled to the transmission input without requiring external alignment. This monobloc construction prevents the generation of noise from misalignment while maintaining design flexibility through standardized interfaces.
4Reliability
If integrated monobloc system is used, then alignment and noise issues are eliminated, but maintenance access becomes difficult
Solution Approach 1:
While maintaining the integrated monobloc structure for alignment precision, the patent incorporates segmentation through removable end covers and access panels that allow maintenance personnel to reach operative systems and maintenance points without disassembling the entire unit. This segmented access approach preserves alignment benefits while improving maintainability.
5Volume of moving object
If compact integrated system is used, then space encumbrance is reduced, but heat dissipation becomes more challenging
Solution Approach 1:
The integrated motor-transmission design allows for shared thermal management infrastructure, where cooling pathways serve both components simultaneously. The unified structure enables efficient heat transfer from motor to transmission housing and surrounding environment, improving heat dissipation despite compact dimensions.
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 solution provides a compact, efficient, and adaptable transmission system with improved alignment, reduced noise, lower costs, and enhanced maintenance accessibility, allowing for different braking systems and increased rotation speed with precise construction, while avoiding the need for additional support and alignment issues.
Implementation Method 1
The motor shaft (4) has the pinion (4) of the first stage of reduction directly on it and directly obtained thereon
Implementation Method 2
brake, which is activated by means of a mechanical lever (12)
Implementation Method 3
the brake chamber (10) communicates by means of said additional chamber /container (8) and duct (7) with the oil chamber of the reducer-transmission (6)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Gearmotor with integrated brake for direct drive to the electric-traction vehicle wheel where the traction motor (13) is integrated with a direct drive (4.3, 5, 2) to the driving-wheel (l), characterized in that said traction motor (13) includes a shaft (4) that: on the wheel side (1) is integrated with a pinion that internally gears in an integrated reducer-transmission system (3.5) for the traction motion to the wheel (1-2) in the respective gear chamber (6); and on the other side opposite the wheel (1) is keyed to a braking system (11) also integrated and cased (9) with the group, in the respective opposite braking chamber (10).