Pass-Through Brushless Motor Layout Without Bevel Gears
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Solution Overview
Problem
Existing brushless DC motors in power tools require complex gear systems to convert rotational motion to reciprocating motion, increasing tool size and complexity.
Innovation Solution
A brushless DC motor design that integrates a stator assembly with coil windings and a rotor assembly, allowing direct conversion of rotational motion to reciprocating motion without the need for direction-changing gears, reducing tool size and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If complex gear systems are used to convert rotational motion to reciprocating motion, then operational functionality is achieved, but tool size and mechanical complexity increase
Solution Approach 1:
The patent extracts and eliminates the complex gear system from the motor assembly, using a direct-drive configuration where the rotor assembly directly converts rotational motion to reciprocating motion through its interaction with the stator assembly, removing the need for intermediate mechanical transmission components
Solution Approach 2:
The patent merges the functions of the motor and motion conversion into a single integrated assembly, where the rotor assembly with its偏心 structure directly performs both rotation and reciprocating motion conversion, combining previously separate functional elements into one unified system
2Ease of operation
If complex gear systems are used to convert rotational motion to reciprocating motion, then operational functionality is achieved, but tool size increases
Solution Approach 1:
The patent removes the gear system that occupied significant space, replacing it with a compact direct-drive mechanism where the rotor assembly's偏心 structure enables motion conversion within a much smaller volume, significantly reducing the overall tool size
Solution Approach 2:
The patent implements a nested configuration where the output drive assembly is positioned within the gap between rotor portions and extends through the stator opening, allowing components to be space-efficiently arranged and reducing the tool's external dimensions
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
Enables compact power tools by eliminating the need for bevel gears, enhancing efficiency and reducing mechanical complexity while maintaining operational functionality.
Implementation Method 1
a motor including a stator assembly having a stator frame with an opening extending therethrough and a plurality of coil windings configured to be selectively powered by the rechargeable battery pack. The motor further includes a rotor assembly disposed within the stator assembly and configured to rotate as the plurality of coil windings are powered by the rechargeable battery pack
Data Source
AI summary
A power tool includes a housing, a rechargeable battery pack coupled to the housing, and a motor supported by the housing. The motor includes a stator assembly having a stator frame with an opening extending therethrough and a plurality of coil windings configured to be selectively powered by the rechargeable battery pack. The coil windings are positioned adjacent the opening of the stator frame. The motor further includes a rotor assembly disposed within the stator assembly and configured to rotate as the coil windings are powered by the rechargeable battery pack. Moreover, the power tool includes an output drive assembly supported by the housing. The output drive assembly extends through the opening of the stator frame to be operably coupled to the rotor assembly.