Integrated Motor Unit With Universal Flange for Compact High Power
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Solution Overview
Problem
Existing motor units for power equipment lack a compact, efficient, and adaptable solution for providing high power output while being easily integrable with various power equipment designs.
Innovation Solution
A stand-alone motor unit with a housing, flange, and power take-off shaft, equipped with an electric motor, battery pack, and controller, featuring a bolt pattern matching common power equipment designs, and incorporating a gearbox and shaft subassemblies for torque transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a high power output of at least 2760 W is provided, then the power capability is improved, but the size and compactness deteriorate
Solution Approach 1:
The patent combines the electric motor, battery pack, controller, and power take-off shaft into a single integrated motor unit assembly. This merging of previously separate components achieves high power output (at least 2760 W) while maintaining compact dimensions (nominal diameter up to 80 mm), as the components share common housing and mounting structures rather than requiring separate installations.
2Volume of moving object
If the motor unit is made compact with a nominal diameter of up to 80 mm, then the space efficiency is improved, but the power output capability deteriorates
Solution Approach 1:
The patent employs a nested arrangement where the controller is positioned within the housing, the battery pack is integrated into the assembly, and the power take-off shaft protrudes from the housing. This nesting of components within each other's spatial envelopes enables the motor unit to achieve compact dimensions (nominal diameter up to 80 mm) while still accommodating high power output components (at least 2760 W).
3Adaptability or versatility
If the bolt pattern is designed to match common power equipment designs, then the adaptability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent designs the flange with a bolt pattern that matches common power equipment designs, enabling the motor unit to be universally adapted to various power equipment applications. This universal interface design achieves compatibility across different equipment types while the standardized flange geometry maintains manufacturing simplicity through repeated use of common machining operations.
4Adaptability or versatility
If an integrated motor unit with multiple components is created, then the integration capability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the electric motor, battery pack, controller, and power take-off shaft into a single integrated motor unit with a common housing and unified mounting interface. This consolidation improves integration capability by providing a complete ready-to-install assembly while reducing device complexity through the elimination of separate mounting brackets, wiring harnesses, and alignment procedures that would be required if the components were installed separately.
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 motor unit provides a high power output of at least 2760 W, is compact with a nominal diameter of up to 80 mm, and is adaptable to various power equipment designs, enhancing efficiency and integration capabilities.
Implementation Method 1
a battery pack including a pack housing, battery cells supported by the pack housing, and a first terminal electrically connected to the battery cells
Implementation Method 2
an electric motor located within the housing and having a power output of at least about 2760 W and a nominal diameter of up to about 80 mm. The motor includes a stator and a rotor supported for rotation relative to the stator
Data Source
AI summary
A stand-alone motor unit for use with a piece of power equipment includes a housing and a flange coupled to the housing on a first side thereof. A plurality of apertures through the flange defines a first bolt pattern that matches an identical, second bolt pattern defined in the piece of power equipment. An electric motor has a power output of at least about 2760 W. The motor includes a stator having a nominal outer diameter of up to about 80 mm and a rotor supported for rotation within the stator. A power take-off shaft receives torque from the rotor and protrudes from one of the flange or a second side of the housing. A controller is positioned within the housing and electrically connected to the motor. A battery pack for powering the motor has battery cells having a nominal voltage of up to about 80 V.