Gearless Roller Motor with Keyed Rare Earth Magnets
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Solution Overview
Problem
Conveyor systems require a motor that is shaped as a roller, with a sintered or hot pressed ring magnet connected to a roller tube via keying for secure alignment and sufficient torque, replacing traditional gear-type motorized rollers.
Innovation Solution
A motor comprising a roller shaft connected to motor stators, a roller tube with a key or key recess, and radially magnetized ring magnets made from rare earth metals like neodymium, iron, and boron, or samarium and cobalt, formed through sintering or hot pressing, ensuring secure mating and sufficient torque without gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a gear box is used in traditional motorized rollers, then sufficient torque can be achieved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent removes the gear box from the motorized roller design, extracting the complex mechanical transmission component while maintaining sufficient torque output through direct drive configuration with optimized motor and roller integration
Solution Approach 2:
The patent replaces the mechanical gear transmission system with a direct electromagnetic drive system, where the motor rotor is directly coupled to the roller, eliminating the need for mechanical gears and reducing overall system complexity
2Manufacturing precision
If ring magnets are produced using sintering or hot pressing, then manufacturing precision and magnetic properties improve, but the manufacturing process complexity increases
Solution Approach 1:
The patent utilizes sintering or hot pressing processes with controlled temperature and pressure parameters to achieve precise dimensional accuracy and optimized magnetic properties of the ring magnets, transforming material properties through controlled physical changes
3Manufacturing precision
If a keying system is used to connect ring magnets to roller tube, then alignment precision and mechanical strength improve, but the device complexity increases
Solution Approach 1:
The patent incorporates keying features directly into the roller tube and corresponding keyways into the ring magnets during the manufacturing process, establishing precise alignment and mechanical connection before assembly, thereby eliminating the need for separate alignment operations
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 provides a gearless motor with easy manufacturing and sufficient torque to replace traditional gear-type motorized rollers, enhancing conveyor system efficiency and reliability.
Implementation Method 1
the one or more ring magnets are produced from a rare earth metal and the one or more ring magnets are sintered, hot pressed, or both
Implementation Method 2
the one or more ring magnets are produced from a rare earth metal and the one or more ring magnets are sintered, hot pressed, or both
Implementation Method 3
A motor comprising: (a) one or more motor stators including a plurality of motor windings; (c) a motor rotor including: (ii) one or more ring magnets; wherein the one or more ring magnets are magnetized radially with multi poles
Data Source
AI summary
A motor comprising: (a) one or more motor stators including a plurality of motor windings; (b) a roller shaft connected to the one or more motor stators, the roller shaft extending along a longitudinal axis of the motor and being adapted to span between two frame members; and (c) a motor rotor including: (i) a roller tube including a key, a key recess, or both, and (ii) one or more ring magnets having: (1) a mating surface shaped to substantially mate to a mating surface of the roller tube and (2) a key recess that receives the key of the roller tube, that receives a separate key that extends into the key recess of one of the one or more ring magnets and the key recess, or both; wherein the one or more ring magnets are produced from a rare earth metal; and wherein the motor rotor carries a load of an article so that the article is moved by the motor rotor.