Integrated Motor Coupler Adaptor for Compact Actuator Systems
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Solution Overview
Problem
Existing motor and screw combinations face issues with excess length due to coupler arrangements, leading to assembly and stocking problems, and custom solutions that complicate part replacement.
Innovation Solution
A coupler arrangement using a split collar adaptor with a non-round coupling recess and a knurled coupling shaft that adjusts to fit various driven shafts, reducing overall system length while allowing for easy removal and replacement, and improving torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional coupler arrangement is used to connect the motor and screw, then the assembly is straightforward and components are easily replaceable, but the overall system length increases excessively
Solution Approach 1:
The adaptor integrates multiple functions into a single component: it combines the coupling shaft that inserts into the motor rotor with the collar that clamps onto the screw shaft, eliminating the need for separate coupler and mounting bracket components. This merging reduces the number of parts and overall assembly length while maintaining ease of assembly and replacement capabilities.
Solution Approach 2:
The coupling shaft is nested within the motor rotor through the central bore, while the collar is positioned at the end of the coupling shaft to engage the screw. This nested arrangement allows the components to be compactly arranged along the axial direction, reducing the overall length of the motor-screw assembly while preserving the ability to easily assemble and disassemble the components.
2Length of moving object
If the screw shaft is directly welded to the motor to shorten length, then the overall length is reduced, but the motor-shaft combination becomes custom and replacement parts become difficult
Solution Approach 1:
The adaptor is designed as a universal interface that can accommodate different screw shaft diameters through the adjustable collar mechanism, while the coupling shaft with knurled outer periphery provides a standard connection to the motor rotor. This universal design allows the same adaptor to work with various screw types, maintaining interchangeability and ease of stocking replacement parts while achieving the shortened length goal.
Solution Approach 2:
The connection between motor and screw is segmented into three distinct parts: the coupling shaft that interfaces with the motor rotor, the collar that clamps onto the screw shaft, and the adaptor body that holds these components together. This segmentation allows each part to be independently manufactured and replaced, avoiding the need for custom welded assemblies while achieving compact dimensions.
3Adaptability or versatility
If a standard coupler is used with motor mount, then components are easily stocked and replaced, but the motor must be spaced away from the end block causing excess length
Solution Approach 1:
The adaptor merges the functions of the coupler and motor mount into a single integrated component that attaches directly to the end block. The coupling shaft extends into the motor rotor while the collar engages the screw shaft, eliminating the need for a separate motor mount bracket. This integration allows the motor to be positioned closer to the end block, reducing the overall mounting length while maintaining standardized, easily replaceable components.
Data Source
AI summary
Couplings between driven shafts of an actuator and a motor of an actuator are provided. The coupling may be directly integrated into a rotor of the motor. The coupling may be provided by an adaptor that includes a shaft that extends into a central bore of the rotor of the motor. The adaptor can include a collar that defines a coupling recess that receives a distal end of the driven shaft of the actuator. The collar may take the form of a clamp.