Sealed Electric Motor Housing for Watertight Sensor Integration
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Solution Overview
Problem
Existing electric lawn mowers face challenges in providing a robust and efficient mechanism to control and mount motors, ensuring compactness, and maximizing runtime and cutting area, while effectively managing power distribution and regenerative energy in battery-operated systems.
Innovation Solution
The design incorporates a frame with a motor control panel featuring thermally-conductive mounting frames, inverter circuits, and regenerative energy control modules, along with brushless direct-current (BLDC) motors and a battery system that optimizes power distribution and energy management, including regenerative energy absorption, to enhance motor control and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a motor control panel with inverter circuits and control modules is added to control power supply to motors, then motor control precision and efficiency are improved, but device complexity increases
Solution Approach 1:
The patent integrates the control module, inverter circuit, and motor mounting structure into a single integrated motor control panel assembly. This merging of functions reduces the number of separate components and simplifies the overall control system architecture while maintaining precise motor control capabilities through the integrated design.
2Temperature
If thermally-conductive mounting frames are used to mount control modules, then heat dissipation and thermal management are improved, but manufacturing complexity increases
Solution Approach 1:
The mounting frame serves multiple functions simultaneously: it mechanically supports the control module, provides thermal conduction pathways for heat dissipation, and acts as a structural component of the motor control panel. This multi-functionality reduces the need for separate heat sink components and simplifies the overall manufacturing process.
3Duration of action of moving object
If battery packs are mounted side-by-side in a battery compartment, then energy capacity and runtime are increased, but volume and space requirements increase
Solution Approach 1:
The battery packs are arranged in a compact side-by-side configuration within the battery compartment, optimizing the use of available space. The design nests the battery packs efficiently to maximize energy capacity while minimizing the overall volume occupied by the battery system.
4Loss of energy
If regenerative energy absorbing modules are integrated into the motor control panel, then energy recovery and efficiency are improved, but device complexity increases
Solution Approach 1:
The regenerative energy absorbing modules are integrated directly into the motor control panel assembly, merging the energy recovery function with the existing control structure. This integration allows the system to capture and store regenerative energy during motor deceleration without requiring a completely separate energy management system.
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 solution enables improved motor control, increased runtime, and efficient power management, allowing for a more compact and robust electric lawn mower with enhanced performance and energy utilization.
Implementation Method 1
at least one of the plurality of control modules comprises a mounting frame made of thermally-conductive material fastened to the plate
Implementation Method 2
brushless direct-current (BLDC) motors
Implementation Method 3
regenerative energy control modules, along with brushless direct-current (BLDC) motors and a battery system that optimizes power distribution and energy management, including regenerative energy absorption
Data Source
AI summary
An electric motor is provided including a stator, a rotor, a motor spindle coupled to the rotor and extending along a center axis, a first end cap formed on a first side of the stator, a second end cap formed on a second side of the stator and secured to the first end cap to form a first compartment around the stator and the rotor, and a motor component mounted on the second end cap outside the first compartment. A motor cover is mounted on the second end cap to form a second compartment around the motor component. The first end cap, the second end cap, and the motor cover form a substantially watertight seal around the stator, the rotor, and the position sensor assembly.