Integrated Motor Module for Powered Roller Assembly
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Solution Overview
Problem
The conventional manufacturing process of the driving device in conveyor systems is labor-intensive and time-consuming due to the need for multiple parts to be inserted and connected within a long cylinder, which also complicates maintenance and replacement.
Innovation Solution
A motor module that integrates the bearing base, stator, rotor, fixing base, and circuit board into a single module, which is then mounted within the driving device cylinder and connected to a reduction gearbox, simplifying the manufacturing process by allowing all components to be installed in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts (bearing base, stator, rotor, circuit board) are inserted separately into the driving device cylinder, then each part can be independently manufactured and assembled, but the manufacturing process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent combines the bearing base, stator, rotor, and circuit board into a single integrated motor module assembly. This allows all components to be pre-assembled and tested as one unit before insertion into the driving device cylinder, eliminating the need for separate insertion and connection steps during final assembly, thereby significantly improving manufacturing productivity.
Solution Approach 2:
The motor module components are assembled and connected in advance before being installed into the driving device cylinder. The bearing base, stator, rotor, and circuit board are pre-positioned and electrically connected within the motor module housing, so that during final assembly, the entire pre-assembled motor module is inserted as a single unit, reducing on-site assembly time and labor.
2Adaptability or versatility
If multiple parts are inserted separately into the driving device cylinder, then component independence is maintained, but the manufacturing process requires frequent forward and backward movements increasing labor and time
Solution Approach 1:
The patent integrates multiple independent components (bearing base, stator, rotor, circuit board) into a unified motor module assembly that functions as a single insertable unit. This merging eliminates the need for repeated insertion and withdrawal operations during assembly, reducing assembly time while maintaining the functional independence of each component within the integrated module.
3Device complexity
If the driving device cylinder is made longer to accommodate more parts, then all components can be housed in a single cylinder, but the insertion process becomes more laborious and time-consuming
Solution Approach 1:
The patent combines multiple components into a compact motor module assembly that fits within the existing driving device cylinder dimensions. By integrating the bearing base, stator, rotor, and circuit board into a space-efficient unified structure, the design accommodates all necessary parts in a single cylinder without requiring extended cylinder length, thereby maintaining ease of insertion while achieving complete component housing.
4Ease of repair
If multiple separate parts are assembled in the driving device cylinder, then component replacement is possible, but maintenance and replacement become more complex
Solution Approach 1:
The patent integrates the bearing base, stator, rotor, and circuit board into a unified motor module assembly. This integration simplifies maintenance and replacement by treating the entire motor module as a single replaceable unit, reducing the complexity of disassembly and reassembly operations while maintaining the functional replaceability of the motor assembly.
Data Source
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AI summary
A motor module has a bearing base (10), a stator (20), a rotor (30), a fixing base (40), and a circuit board (50). The bearing base (10), the stator (20), and the fixing base (40) are sequentially and securely mounted to each other. The bearing base (10) has a bearing base casing (11). The stator (20) has a stator casing (21). The fixing base (40) has a fixing base casing (41). Two end surfaces of the stator casing (21) are respectively connected to an end surface of the bearing base casing (11) and an end surface of the fixing base casing (41). The rotor (30) is mounted in the stator (20), and is mounted through the bearing base (10). The circuit board (50) is mounted in the fixing base (40) and is electrically connected to the stator (20).