Powered Roller Motor Module Assembly for Single-Step Installation
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Solution Overview
Problem
The conventional manufacturing process of motor modules for conveyor systems is labor-intensive and time-consuming due to the need for separate insertion and soldering of multiple parts, which complicates assembly and maintenance.
Innovation Solution
A modular motor module that integrates the bearing base, stator, rotor, and circuit board, allowing for simultaneous installation within a driving device cylinder, reducing the complexity and labor required for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple parts (bearing base, stator, rotor, circuit board) are inserted separately into the driving device cylinder, then each part can be individually installed, but the manufacturing process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent combines the bearing base, stator, rotor, and circuit board into a single integrated motor module assembly. This merging of multiple separate components into one unified module allows the entire assembly to be inserted into the driving device cylinder in a single operation, eliminating the need for separate insertion and soldering steps for each component, thereby significantly improving manufacturing efficiency while maintaining ease of assembly through modular design
2Device complexity
If the driving device cylinder is made longer to accommodate more parts, then all components can be housed in one cylinder, but the insertion process becomes more complex and laborious
Solution Approach 1:
The patent integrates the bearing base, stator, rotor, and circuit board into a compact motor module that fits within the existing driving device cylinder dimensions. By merging these components into a single pre-assembled unit with standardized outer diameter, the design avoids the need for a longer cylinder while simplifying the insertion process to a single straightforward operation rather than multiple complex insertion steps
3Ease of repair
If separate parts are inserted into the driving device cylinder, then each component can be individually maintained, but maintenance and replacement become more difficult
Solution Approach 1:
The patent creates an integrated motor module where the bearing base, stator, rotor, and circuit board are combined into a single replaceable unit. This merging simplifies maintenance and replacement operations, as the entire motor module can be removed and installed as one complete assembly, reducing maintenance complexity despite the internal integration of multiple components
Solution Approach 2:
The patent segments the conveyor system into modular components, with the motor module being one such segment. This segmentation allows the motor module to be independently maintained or replaced without affecting other parts of the system, improving ease of repair while the internal integration reduces overall assembly complexity
Data Source
AI summary
A motor module has a bearing base, a stator, a rotor, a fixing base, and a circuit board. The bearing base, the stator, and the fixing base are sequentially and securely mounted to each other. The bearing base has a bearing base casing. The stator has a stator casing. The fixing base has a fixing base casing. Two end surfaces of the stator casing are respectively connected to an end surface of the bearing base casing and an end surface of the fixing base casing. The rotor is rotatably mounted in the stator, and is rotatably mounted through the bearing base. The circuit board is mounted in the fixing base and is electrically connected to the stator.