Electric Drive Motor Sealing and Brake Layout for 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 and regenerative energy in battery-operated systems.
Innovation Solution
The design incorporates a frame with a motor control panel featuring thermally-conductive mounting frames, inverter circuits, and regenerative energy control modules, along with brushless direct-current (BLDC) motors and a battery system that optimizes power distribution and energy management, including regenerative energy absorption, to enhance motor control and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a motor control panel with inverter circuits and regenerative energy control modules is integrated into the lawn apparatus, then power distribution efficiency and energy utilization are improved, but device complexity increases
Solution Approach 1:
The patent integrates the motor control panel, inverter circuits, and regenerative energy control modules into a unified control system that manages power distribution to multiple motors and handles regenerative braking functions. This merging of previously separate functions into a single integrated panel improves power distribution efficiency while consolidating complexity into one manageable unit rather than分散 across multiple separate systems.
Solution Approach 2:
The motor control panel serves multiple functions simultaneously: it controls the drive motors, manages deck motors, handles regenerative energy recovery, and distributes power from the battery system. This multi-functionality allows a single device to improve overall power distribution efficiency across the entire system while avoiding the need for separate specialized control systems for each function.
2Reliability
If BLDC motors with thermally-conductive mounting frames are used, then motor performance and heat dissipation are improved, but manufacturing complexity increases
Solution Approach 1:
The mounting frame combines thermally-conductive materials with structural metal components to create a composite assembly that provides both mechanical support and heat dissipation functionality. This use of composite materials allows the motor assembly to achieve improved thermal management and motor performance while the modular composite structure can be manufactured using standard fabrication techniques for each material type, followed by assembly.
Solution Approach 2:
The thermally-conductive mounting frame merges the structural support function with the heat dissipation function into a single integrated component. Instead of requiring separate mounting brackets and heat sinks, the mounting frame itself provides both functions, improving motor performance through better thermal management while reducing the number of discrete parts that need to be manufactured and assembled.
3Loss of energy
If regenerative energy absorption is implemented, then energy utilization is improved, but device complexity increases
Solution Approach 1:
The regenerative energy control module captures energy that would otherwise be lost during motor deceleration and braking, converting it into usable electrical energy that is stored in the battery system. This transforms the harmful energy dissipation that occurs during regenerative braking into a beneficial energy recovery mechanism, reducing overall energy loss and improving fuel efficiency.
Solution Approach 2:
The regenerative energy control system continuously monitors motor operation, battery charge state, and energy flow to dynamically adjust the regenerative braking engagement and power distribution. This feedback mechanism ensures optimal energy recovery while preventing overcharging or excessive regenerative braking that could damage the system, thereby managing the added complexity through intelligent control algorithms.
4Area of stationary object
If multiple deck motors are mounted on the mow deck, then cutting area coverage is improved, but device complexity increases
Solution Approach 1:
The mowing system is divided into multiple independent motor-deck units, each with its own BLDC motor and mow deck assembly. This segmentation allows each motor to independently drive its own deck, providing better coverage of the cutting area while allowing each motor unit to be manufactured, tested, and maintained as a separate module, thereby managing the complexity through modularity.
Solution Approach 2:
Each deck motor is designed to perform multiple functions: driving the mow deck rotation, providing torque for cutting through various grass conditions, and enabling regenerative energy recovery during deceleration. This multi-functionality allows the system to achieve comprehensive cutting area coverage with motor units that are versatile rather than specialized, reducing the need for additional components.
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 enables efficient power management, extended runtime, and improved motor performance, ensuring robust operation and effective energy utilization in electric lawn mowers.
Implementation Method 1
thermally-conductive mounting frames
Implementation Method 2
brushless direct-current (BLDC) motors
Implementation Method 3
regenerative energy control modules
Data Source
AI summary
An electric motor is provided including a stator, a rotor, a motor spindle coupled to the rotor and extending along a center axis, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a first compartment around the stator and the rotor, an electro-magnetic brake module disposed on a side of the second end cap opposite the stator and engaged with the motor spindle, and a motor cover mounted on the second end cap to form a second compartment around the electro-magnetic brake module. The first end cap, the second end cap, and the motor cover form a substantially watertight seal around the stator, the rotor, and the position sensor assembly.