Low-Profile BLDC Motor Mounting With Integrated Power Control

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Solution Overview

Problem

Existing electric lawn mowers face challenges in providing a robust and efficient mechanism to control and mount motors, ensuring compactness, and maximizing runtime and cutting area, while effectively managing power distribution and regenerative energy.

Innovation Solution

The design includes a frame with an upper body, side plates, and a lower support body, featuring drive motors, deck motors, a battery system, and a motor control panel with thermally-conductive materials, power switches, and regenerative energy control modules to manage power distribution and energy absorption efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a motor control panel is integrated into the lower support body, then motor control and power management are enhanced, but device complexity increases

Engineering Contradiction:

Improvemotor controlVSAvoidcontrol panel integration

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The motor control panel is integrated into the lower support body by securing it directly to the frame structure, combining multiple functions (motor control, power distribution, regenerative energy management) into a single unified component rather than separate modules

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The control panel serves multiple functions simultaneously: controlling drive motors, controlling deck motors, managing battery power distribution, and handling regenerative energy absorption, making one component perform several critical system functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If thermally-conductive materials are used in control modules, then heat dissipation is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveheat dissipationVSAvoidmanufacturing complexity

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

Thermally-conductive materials are applied specifically to the control module housing and mounting structures where heat generation occurs, rather than throughout the entire device, providing targeted thermal management where needed

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The control module housing incorporates thermally-conductive materials that may be combined with other materials to achieve both thermal management and structural requirements, using composite construction to address multiple performance criteria simultaneously

Inventive Principle:

Principle #40Composite materials

3Loss of energy

If regenerative energy control modules are added, then energy efficiency is improved, but device complexity increases

Engineering Contradiction:

Improveregenerative energy utilizationVSAvoidcontrol module quantity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The system captures energy that would otherwise be lost during motor deceleration or braking and converts it back into electrical energy stored in the battery, transforming waste energy into useful power

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The regenerative energy control modules continuously monitor system conditions and automatically activate or deactivate based on whether regenerative braking conditions are present, creating a self-regulating energy recovery system

Inventive Principle:

Principle #23Feedback

4Power

If multiple control modules are mounted on a plate, then power distribution is improved, but device complexity increases

Engineering Contradiction:

Improvepower distributionVSAvoidcontrol module arrangement

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

Multiple control modules are mounted together on a single plate structure, consolidating what could be separate distributed components into one organized assembly, simplifying the overall system architecture

Inventive Principle:

Principle #5Merging (Combining)

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 configuration enhances motor control and power management, enabling extended runtime, increased cutting area efficiency, and effective regenerative energy utilization, addressing the challenges of motor control and power distribution in electric lawn mowers.

Implementation Method 1

a mounting frame made of thermally-conductive material fastened to the plate

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240072599A1Low profile electic motor

Publication Date: 2024.02.29 BLACK & DECKER CORP

AI summary

An electric power apparatus includes a main planar body having a circular opening that supports a brushless direct-current (BLDC) motor. The motor includes a stator, a rotor, a motor spindle extending through the circular opening, a first end cap formed on a first side of the stator and mounted on the main planar body; and a second end cap formed on a second side of the stator and secured to the first end cap to form a substantially watertight seal around the stator and the rotor. A ratio of a maximum power output of the motor when powered by at least one battery pack to a height of the motor as measured from an upper surface of the main planar body to a top surface of the motor is greater than or equal to approximately 34 watts/mm.