Integrated Motor Gearbox Nesting in Stator Bore
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Solution Overview
Problem
Existing electrical machines require multiple sizes and configurations of motors and gearboxes to achieve various speed and torque ranges, leading to increased inventory, operating, and maintenance costs, as well as space constraints and heat dissipation issues due to the combination of gearboxes and cooling fans.
Innovation Solution
A motor and gearbox are fully integrated within a single housing, with the gearbox positioned within the stator bore to maximize space efficiency and reduce size, and a heat transfer system is implemented to manage heat dissipation without the need for external fans, allowing for efficient operation in confined spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a gearbox is coupled to the input shaft and output shaft, then speed and torque requirements are met, but the size and axial length of the electrical machine increase
Solution Approach 1:
The gearbox is positioned within the stator bore, nesting the gearbox components inside the existing motor structure. The input shaft extends through the stator bore, the gearbox is mounted on the input shaft within the bore, and the output shaft is positioned within the gearbox, creating a nested configuration that reduces overall size.
Solution Approach 2:
The gearbox is arranged in a radial configuration within the stator bore rather than extending axially. The input shaft rotates about a first axis, the gearbox is positioned at a radial distance from this axis, and the output shaft rotates about a second axis that is radially offset, utilizing radial space instead of axial space.
2Adaptability or versatility
If multiple sizes of motors and gearboxes are used to cover various speed and torque ranges, then application requirements are met, but inventory costs, operating costs, and maintenance costs increase
Solution Approach 1:
The motor assembly with the integrated gearbox within the stator bore creates a universal platform that can serve multiple applications. By adjusting gear ratios within the gearbox or modifying the motor specifications while maintaining the same basic structure, the system can cover various speed and torque ranges without requiring completely different motor and gearbox combinations.
3Volume of moving object
If the gearbox is positioned within the stator bore, then space efficiency is maximized, but manufacturing precision requirements increase
Solution Approach 1:
The bearing assemblies provide localized precision support at critical positions. First bearing assemblies support the input shaft at specific locations within the stator bore, and second bearing assemblies support the output shaft within the gearbox, ensuring proper alignment and reducing the need for extremely tight manufacturing tolerances across the entire assembly.
Data Source
AI summary
A motor has an axis of rotation and includes a housing, a first shaft coupled to the housing, and a second shaft coupled to the first shaft. The motor further includes a stator, a rotor coupled to the first shaft, a gearbox, and a bearing assembly coupled to the rotor. The stator includes an outer circumferential surface and an inner circumferential surface. The inner circumferential surface defines a stator bore around the axis of rotation. The rotor includes a first arm and a second arm. The first arm is configured to extend axially along the axis of rotation and within the stator bore, and the second arm is configured to extend radially from the axis of rotation. The first arm and the bearing assembly are positioned within the stator bore, and the second arm is positioned entirely outside of the stator bore.