Motor-Gearbox Caulked Lug Locking for Adhesive-Free Assembly

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Solution Overview

Problem

Existing methods for connecting a motor to a gearbox face challenges such as unsuitable adhesive use in extreme conditions, visual defects from welding, and complexity in handling adhesives, especially when high loads are applied, and require costly and complex pre-treatment of components.

Innovation Solution

A method involving a form- and/or force-fit connection between the motor and gearbox components, secured by caulking a lug on the first component into a recess on the second component, using a caulking tool with matching teeth to guide the deformation, and optionally creating a circumferential form fit with a profiled front portion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If adhesive is used to secure the screw connection, then the connection is secured against unscrewing, but the adhesive fails in extreme low- or high-temperature applications and in high vacuum

Engineering Contradiction:

Improveconnection securityVSAvoidtemperature range

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the chemical bonding mechanism of adhesives with a mechanical interlocking system consisting of a circumferential groove, radially extending locking elements, and a retaining ring. This mechanical substitution eliminates temperature and vacuum limitations while providing reliable connection security through physical interlocking rather than chemical adhesion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If welding is used to realize screw locking, then the connection is secured, but visual defects such as holes, blowholes and stains occur

Engineering Contradiction:

Improveconnection securityVSAvoidvisual quality

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

The patent replaces the thermal welding process with a cold-forming mechanical interlocking system. The retaining ring with radially extending locking elements mechanically secures the screw connection without melting or fusing materials, thereby eliminating visual defects like holes, blowholes, and stains while maintaining connection security.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If conventional connection methods are used, then the components are connected, but the handling of adhesive is complicated and may be injurious to health

Engineering Contradiction:

Improveconnection processVSAvoidhealth hazards

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent replaces adhesive handling with a mechanical assembly process involving the retaining ring and locking elements. This substitution eliminates health hazards associated with adhesive exposure while simplifying the manufacturing process through straightforward mechanical operations such as inserting the retaining ring and deforming the locking elements into the groove.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Strength

If a screwed connection is used for high loads, then the connection strength is sufficient, but additional securing against unscrewing is required

Engineering Contradiction:

Improveconnection strengthVSAvoidconnection structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the screw connection with the locking mechanism by integrating the retaining ring that features both load-bearing screw engagement and anti-unscrewing locking elements. This merging allows a single component to provide both connection strength and security against unscrewing, thereby reducing overall structural complexity while maintaining high load capacity.

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

Enables a reliable, cost-effective, and precise connection without adhesives or welding, suitable for various materials, with repeat accuracy and no need for pre-treatment, and provides anti-rotation security.

Implementation Method 1

a lug formed on the first component is deformed by means of a caulking tool into a recess formed on the second component

Methodology Applied

Scientific EffectDeformation: Deformation

Implementation Method 2

a lug formed on the first component is deformed by means of a caulking tool into a recess formed on the second component

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS12365021B2Method for connecting two components, in particular a motor to a gearbox, and assembly with a connection between motor and gearbox

Publication Date: 2025.07.22 MAXON MOTOR AG

AI summary

A form- and/or force-fit connection between the motor and the gearbox is established by screwing together a motor- or gearbox-side first component and the respective motor- or gearbox-side second component. Alternately, an interference fit can be established between these two components by way of an axial lock that includes a lug, which formed on the first component, that is deformed by a caulking tool into a recess formed on the second component.