Electric Mower Deck Motor Assembly for Cooling and Debris Control
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Solution Overview
Problem
Existing electric motor assemblies for mowing decks in electrically powered mowing vehicles often suffer from debris accumulation, increased stress on motor components due to elongated adapters, and inefficient cooling, leading to reduced operational efficiency and longevity.
Innovation Solution
The proposed electric mid-mount motor assembly features integrally formed mounting surfaces on an upper housing, allowing for efficient assembly and cooling by positioning a substantial portion of the motor below the mowing deck, where it can benefit from airflow. This design eliminates the need for deep recesses in the deck and reduces stress on motor components by eliminating elongated adapters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the motor is mounted in recesses formed in the deck, then the motor is protected from debris, but debris accumulates around the motor housings and cooling efficiency is reduced
Solution Approach 1:
The motor assembly is extracted from the traditional recessed mounting location and repositioned to mount on the upper surface of the deck. This extraction removes the motor from the debris-prone recess area while allowing the deck recess to be eliminated or reduced in depth, preventing debris accumulation around the motor housing and improving airflow for cooling.
Solution Approach 2:
The motor mounting approach transitions from a vertical recessed configuration to a horizontal upper-surface mounting configuration. This dimensional change allows the motor to be positioned where cooling airflow can access it more effectively while eliminating the deep recess that trapped debris.
2Shape
If elongated adapters are used to position mower blades properly on flat decks, then blade positioning is achieved, but additional stress is placed on motor output shaft bearings reducing service life
Solution Approach 1:
The elongated adapter component is eliminated by repositioning the motor assembly itself. The motor is mounted on the upper deck surface at a location that provides proper blade positioning without requiring an extended adapter, thereby removing the source of additional stress on the output shaft bearings.
Solution Approach 2:
Instead of extending the blade positioning mechanism (elongated adapter) to achieve proper blade height, the solution inverts the approach by positioning the motor itself on the upper deck surface. This reverses the traditional design paradigm where the motor is recessed and requires long adapters, eliminating the need for stress-inducing extended components.
3Ease of manufacture
If deep recesses are formed in the deck for motor mounting, then motor mounting is achieved, but fabrication complexity and cost increase
Solution Approach 1:
The deep recess feature is extracted from the deck design by mounting the motor on the upper surface instead. This eliminates the need for complex deep recess fabrication while maintaining motor mounting capability, simplifying the overall deck manufacturing process.
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 enhances cooling efficiency, reduces debris accumulation, and decreases stress on motor components, resulting in improved operational efficiency, longevity, and cost savings through simplified deck fabrication.
Implementation Method 1
a substantial portion of the electric motor is situated below the mowing deck and exposed to cooling air flow generated by the rotation of mower blades
Data Source
AI summary
A utility vehicle such as a lawn mower includes a deck having one or more electric deck motor assemblies mounted thereon. Each deck motor assembly includes an electric motor compartment formed by combining a motor end cap, a stator housing and a motor output cap. The motor end cap forms a flat motor mounting surface that seats around the perimeter of an opening in the deck such that the stator housing and motor output cap extend through the opening. The motor compartment contains an electric motor that drives a motor shaft connected to a mowing blade suspended below the deck. Rotation of the mowing blade air-cools the components of the motor compartment that extend through the opening in the deck. The deck motor assembly may include a debris shield for protection of a motor output shaft lower bearing seal during operation and cleaning of the mowing deck.