Integrated Motor Control Panel for Compact Electric Lawn Mowers
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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 to both drive and deck motors.
Innovation Solution
The design includes a frame with an upper body, side plates, and a lower support body, featuring drive motors secured to the side plates, a mow deck with deck motors, and a motor control panel that regulates power supply using a plate with thermally-conductive mounting frames, circuit boards, and power switches, along with regenerative energy control modules to manage battery voltage and optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a motor control panel is added to regulate power supply to drive and deck motors, then power management efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple control functions into a single integrated motor control panel that manages both drive motors and deck motors. The control panel integrates power switches, circuit boards, and control modules into one unified structure, consolidating what would otherwise be separate control systems into a single device that regulates power distribution to all motors from the battery.
Solution Approach 2:
The motor control panel serves multiple functions: it controls power supply to drive motors, controls power supply to deck motors, monitors battery voltage, and coordinates operation across different motor systems. This multi-functional design allows one device to perform what would traditionally require multiple separate control systems.
2Temperature
If thermally-conductive mounting frames are used to mount control modules, then heat dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the thermal parameter of the mounting frame material by specifying thermally-conductive material. This parameter change enables the mounting frame to function as a heat sink, transferring heat away from control modules and power switches to improve thermal management and prevent overheating of critical components.
3Volume of moving object
If the control modules are mounted on a plate facing the footrest platform, then space utilization is improved, but ease of operation decreases
Solution Approach 1:
The patent utilizes the vertical space dimension by mounting control modules on a plate that faces upward toward the footrest platform area. This vertical arrangement allows the control system to be positioned in an otherwise unused space within the frame structure, optimizing the use of available volume without interfering with the operator's workspace or footrest functionality.
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 efficient operation, extended runtime, and increased cutting area coverage while maintaining a compact and robust design.
Implementation Method 1
a mounting frame made of thermally-conductive material fastened to the plate
Implementation Method 2
at least one regenerative energy control module configured to monitor a voltage from the at least one battery, the electric lawn apparatus further comprising at least one regenerative energy absorbing module that is activated by the at least one regenerative energy control module when the voltage from the battery exceeds a voltage threshold
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
An electric lawn apparatus is provided including a frame, an operator seat mounted on an upper body, two drive motors secured two side plates for driving two rear tires, a mow deck secured below a lower support body of the frame that supports at least one deck motor driving a mow blade, a footrest platform secured to the lower support body of the frame, and a motor control panel located between the mow deck and the footrest platform. The motor control panel includes a plate that supports multiple control modules and controls a supply of electric power to the drive motors and the deck motor.