Modular Electric Motor Construction Kit for Versatile Assembly
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Solution Overview
Problem
Existing electric motor designs for handheld tools and drives require a multitude of different parts for varying power requirements and cooling methods, leading to high development complexity, costs, and limited versatility, as specific motors are needed for specific applications due to restricted use of identical components across different tools and environments.
Innovation Solution
An electric motor construction kit utilizing modular components, including a frame module, rotor module, stator module, and fastening module, where most modules are carry-over parts, allowing for the assembly of multiple configurations such as full-cartridge and half-cartridge motors with adaptable cooling systems, enabling the use of identical parts across various electric motor types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different electric motor designs are used for varying power requirements and cooling methods, then the motors can meet specific application requirements, but the development complexity and costs increase due to the multitude of different parts required
Solution Approach 1:
The electric motor is divided into modular components including a stator module, rotor module, and frame module. Each module can be independently configured and assembled to create different motor variants, allowing adaptation to various power requirements and cooling methods without redesigning the entire motor.
Solution Approach 2:
The frame module is designed as a universal component that can accommodate different stator and rotor module configurations. The frame module includes standardized mounting interfaces and cooling system attachments that work across multiple motor variants, reducing the need for application-specific parts.
2Reliability
If specific electric motors are designed for specific applications, then the motors can be optimized for their intended use, but the versatility is limited and identical parts cannot be used across different tools
Solution Approach 1:
By segmenting the motor into standardized modules, the design allows specific optimizations (such as different cooling configurations or power ratings) while maintaining compatibility through common interfaces. This enables both application-specific optimization and cross-tool versatility.
Solution Approach 2:
The modular design allows changing key parameters (power output, cooling method, size) by swapping modules rather than redesigning the entire motor. This maintains reliability through proven module designs while achieving versatility through parameter variation.
3Power
If multiple different parts are used for varying motor configurations, then specific performance requirements can be met, but the development costs and production complexity increase
Solution Approach 1:
Segmenting the motor into standardized modules enables power variation through module selection rather than custom design. The standardized interfaces and assembly processes maintain ease of manufacture while achieving different power outputs through configurable module combinations.
Solution Approach 2:
The universal frame module and standardized interfaces allow the same production line and assembly processes to be used across different motor variants, maintaining ease of manufacture while enabling power output variation through module configuration.
4Device complexity
If a modular design with carry-over parts is used, then development complexity and costs are reduced and versatility is enhanced, but the cooling system requires separate configuration for each motor type
Solution Approach 1:
The frame module incorporates universal cooling system interfaces and mounting points that can accommodate different cooling configurations (external cooling, internal cooling channels, fan attachments). This allows the cooling system to be adapted to specific motor types without requiring a completely different frame design.
Solution Approach 2:
The cooling system is designed as a dynamic, configurable component rather than a fixed part of the motor. Different cooling solutions can be attached or integrated into the frame module depending on the specific motor variant, allowing flexibility while maintaining a common base structure.
Data Source
AI summary
An electric motor construction kit for assembling a plurality of electric motors includes at least one module and a plurality of assemblies for constructing the plurality of electric motors. At least one assembly of the plurality of assemblies includes one or more modules of the at least one module. Apart from a cooling system of an electric motor of the plurality of electric motors, each module of the at least one module is constructed from carry-over parts.