Rotor Gear Mounting Assembly Compact Design
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Solution Overview
Problem
The direct press-fit mounting of a drive gear onto a rotor shaft in generators poses packaging challenges due to the need for the drive gear to have a diameter at least as large as the rotor shaft, limiting compact design possibilities.
Innovation Solution
A rotor gear mounting assembly that includes a magnetic member arrangement with a hub portion of smaller diameter than the rotor shaft, allowing for a smaller gear to be coupled via threaded engagement, along with a method of mounting the rotor gear to the hub portion using a pilot component for precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drive gear is press-fit directly onto the rotor shaft, then the gear can be securely mounted, but the gear diameter must be at least as large as the rotor shaft, creating packaging challenges
Solution Approach 1:
A hub component is introduced as an intermediary between the rotor shaft and the drive gear. The hub has a first diameter smaller than the rotor shaft diameter, allowing the gear to be mounted on the hub rather than directly on the shaft. This mediator enables the gear to be securely attached while reducing the overall gear diameter and improving packaging.
Solution Approach 2:
The mounting assembly is segmented into separate components: the rotor shaft, the hub (with smaller diameter), and the drive gear. This segmentation allows each component to be optimized independently, with the hub serving as a reduced-diameter mounting surface that doesn't require the full rotor shaft diameter.
2Volume of moving object
If a hub portion with smaller diameter than the rotor shaft is used, then a smaller gear can be accommodated, but an additional component is introduced
Solution Approach 1:
The hub portion is integrally formed with the magnetic member arrangement, merging two functions into a single component. The magnetic member arrangement provides magnetic coupling between the rotor and stator, while the integrated hub provides the mounting surface for the drive gear. This integration reduces the number of separate parts while achieving the goal of smaller gear diameter.
3Ease of operation
If threaded engagement is used to couple the gear to the hub, then easier installation and removal is achieved, but additional manufacturing features are required
Solution Approach 1:
The patent replaces traditional mechanical keyway or splined connections with threaded engagement. The drive gear is coupled to the hub portion through threads, allowing for easier assembly and disassembly compared to press-fit or keyed connections. This mechanical substitution simplifies installation and removal operations while the threaded features can be manufactured using standard machining processes.
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 enables a more compact design by accommodating a gear of smaller dimensions, addressing packaging challenges and facilitating easier installation and removal of the rotor gear.
Implementation Method 1
a magnetic member arrangement (32) with a hub portion (36) of smaller diameter than the rotor shaft
Data Source
Figure 1
Figure 2~3
AI summary
A rotor gear mounting assembly for a generator (10) includes a rotor shaft (14) comprising a first end (26) and a second end, a magnetic member arrangement (32) operatively coupled to the rotor shaft (14) proximate at least one of the first end (26) and the second end, a hub portion (36) of the magnetic member arrangement (32) and a rotor gear (46) operatively coupled to the hub portion (36).