Nested Dual-Bearing Flat Brushless Motor for Low Backlash Stability
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Solution Overview
Problem
Brushless motors face challenges in achieving a flat design while maintaining high torque output, precision control, and stability, especially in applications requiring precise guidance and tracking, due to limitations in traditional dual-bearing structures that sacrifice durability and stability for compactness.
Innovation Solution
A nested dual-bearing design is implemented, where a first bearing is nested within the inner ring of a second bearing, supported by a support assembly, and forces are cyclically transmitted through nesting and support assembly to reduce backlash, enhancing stability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional dual-bearing structure is used to improve load capacity, then the motor can handle higher loads, but the motor cannot achieve a flat design and compact structure
Solution Approach 1:
The patent applies nesting by placing the first bearing inside the inner ring of the second bearing, creating a nested dual-bearing structure. This allows two bearings to occupy a reduced axial space while maintaining their load-bearing functions, thereby achieving both high load capacity and flat design in the motor
2Shape
If the bearing size is reduced to achieve flat design, then the motor achieves compact structure, but the stability and durability of the motor are sacrificed
Solution Approach 1:
By nesting the first bearing within the second bearing, the patent achieves compact axial dimensions for flat design while maintaining the full size and load-bearing capacity of both bearings. The nested configuration allows larger bearings to provide adequate support without increasing the overall motor height, thus preserving stability and durability
3Shape
If a nested dual-bearing structure is used to achieve flat design, then the motor achieves compact structure, but the complexity of bearing support increases
Solution Approach 1:
The nested bearing structure inherently simplifies the support system by eliminating the need for separate mounting features for two parallel bearings. The inner bearing is supported by the outer bearing's inner ring, reducing the number of independent support elements required and simplifying the overall bearing support architecture
Data Source
AI summary
A nested dual-bearing flat brushless motor includes a first end cap, a second end cap, a connection end cap therebetween, a first connection shaft on a side of the first end cap facing the second end cap, a first connection groove on the second end cap for accommodating the first connection shaft, a second connection shaft on a side of the second end cap facing the first end cap, a second connection groove on the first end cap for accommodating the second connection shaft, a first bearing and a second bearing in the second connection groove, and a support assembly for supporting the first bearing and the second bearing, the first bearing is nested in an inner ring of the second bearing, and the second connection shaft is disposed between an outer ring of the first bearing and the inner ring of the second bearing.