Detachable Motor Test Stall Coupling for Full-Angle Braking
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Solution Overview
Problem
Conventional stall mechanisms for motor testing are limited by non-continuous stall angles and axial installation, leading to complex calibration, alignment issues, and increased moment of inertia, which complicates origin matching and extends testing time.
Innovation Solution
A full-open and full-angle stall device with a detachable driving source connection module and brake module, allowing non-axial installation and full-angle braking, enabling easy installation/removal and flexible stall positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional stall disc with insert pins is used, then the stall function can be achieved, but the stall angle is limited to discrete positions and complex calibration procedures are required
Solution Approach 1:
The patent replaces the mechanical insert pin system with a magnetic field-based positioning system. The stall disc contains magnetic elements that interact with sensors to provide continuous angle feedback, eliminating the need for mechanical pin insertion at discrete positions. This substitution transforms the stall mechanism from a purely mechanical system to one that incorporates magnetic field sensing, enabling continuous angle adjustment without complex calibration procedures.
Solution Approach 2:
The patent introduces magnetic field sensing as an intermediary between the stall disc and the control system. The magnetic sensors detect the position of magnetic elements on the stall disc and provide continuous angular position feedback to the control system, enabling precise angle control without direct mechanical coupling or calibration procedures. This intermediary system bridges the gap between mechanical stalling and electronic control.
2Ease of manufacture
If the stall disc is installed axially on the driving shaft, then the installation is straightforward, but the moment of inertia increases and cannot be reduced when not needed
Solution Approach 1:
The patent divides the stall mechanism into separable components: a drive shaft assembly and a stall disc assembly that can be independently mounted and removed. The stall disc is mounted radially on the drive shaft through a coupling mechanism rather than being axially fixed, allowing it to be easily attached when needed and removed when not needed. This segmentation enables the moment of inertia to be reduced by removing the stall disc for tests that do not require stalling functionality.
Solution Approach 2:
The patent implements a dynamic configuration where the stall disc can be mounted and removed from the drive shaft based on test requirements. The radial mounting mechanism with coupling allows for quick attachment and detachment, transforming the system from a static configuration to a dynamic one where the moment of inertia can be adjusted by removing the stall disc when stalling is not required, thereby improving rotational acceleration performance.
3Adaptability or versatility
If the stall disc is permanently installed on the driving shaft, then the stall function is always available, but devices for other test items cannot be installed and the moment of inertia cannot be reduced
Solution Approach 1:
The patent segments the test system into modular components where the stall disc is a separate, removable module that can be mounted on the drive shaft when needed and removed when not needed. This modular design allows different test devices to be installed on the drive shaft depending on the specific test requirements, maximizing system versatility while maintaining the ability to reduce moment of inertia by removing unnecessary components.
Solution Approach 2:
The patent creates a dynamically reconfigurable test system where the stall disc and other test devices can be mounted or removed from the drive shaft based on the specific test requirements. The radial mounting mechanism enables quick changes in system configuration, allowing the moment of inertia to be minimized by removing the stall disc for high-speed testing applications while maintaining full stall functionality when required.
4Ease of manufacture
If the stall disc is installed by axial insertion, then the installation is simple, but complex alignment and calibration procedures are required during removal and reinstallation
Solution Approach 1:
The patent replaces the axial mechanical insertion system with a radial mounting system that uses a coupling mechanism. This substitution eliminates the complex alignment requirements of axial insertion because the radial mounting allows the stall disc to be attached perpendicular to the drive shaft axis, where alignment is inherently simpler and does not require precise angular positioning or calibration procedures during installation and removal.
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
The solution simplifies calibration and alignment processes, reduces moment of inertia, and enhances operational convenience by allowing flexible stall angle adjustment and quick removal of the stall device when not needed, improving motor test system functionality.
Implementation Method 1
the brake module is controlled to generate a clamping force on the driving source connection module
Data Source
AI summary
A full-open and full-angle stall device for a motor test system is disclosed. The stall device is used to provide a stall function to a motor under test and includes a base, a driving source connection module and a brake module. The driving source connection module includes a coupling and a first disc and a second disc that are detachably joined together. The first disc and the second disc are fixed on the coupling. The coupling is defined with a mounting hole for connecting a transmission shaft so as to receive a driving source from the motor under test. The brake module is disposed on the base and is configured at an edge of the driving source connection module, and is controlled to generate a clamping force on the driving source connection module, wherein the clamping force is selectively applied to any edge of the first disc and the second disc so as to brake the driving source connection module.