Shedding Motor Rotor Layout for High Torque Without Reducers
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Solution Overview
Problem
Existing shedding machines for looms face challenges with high rotational inertia, excessive energy consumption, and low efficiency due to the use of electric actuators with low torque, which are constrained by space and inertia requirements, and the addition of reducers leads to inefficiencies and increased cost.
Innovation Solution
A shedding machine design featuring a rotary electric motor with a rotor shaft and cylindrical part that minimizes inertia, utilizing a stator with laminations and permanent magnets to achieve high torque without mechanical reducers, allowing efficient operation at nominal speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a reducer is added at the output of the motor rotor, then higher torque is obtained at the output, but the efficiency decreases due to reducer losses and the moment of inertia increases significantly
Solution Approach 1:
The patent replaces the mechanical reducer system with an electromagnetic torque amplification system. The inner rotor generates a magnetic field that interacts with the outer rotor to produce amplified torque directly at the motor output, eliminating the need for mechanical gears and reducing energy losses while maintaining high torque output.
2Use of energy by moving object
If the rotational inertia of the motor rotor is minimized, then vibrations and energy consumption are reduced, but the torque capability decreases
Solution Approach 1:
The patent applies local quality by creating a concentrated magnetic field interaction zone between the inner and outer rotors. The magnetic field is localized in the air gap between the rotors, allowing torque amplification to occur in a specific region without requiring the entire rotor assembly to have high inertia.
Solution Approach 2:
The motor employs a composite structure with two separate rotors (inner and outer) that work together magnetically. This composite design allows the system to achieve high torque through magnetic interaction while keeping individual rotor inertias low, as neither rotor needs to independently generate the full torque.
3Volume of moving object
If the space available for arranging motors is constrained, then the motor size is reduced, but the torque capability is limited
Solution Approach 1:
The patent implements a nested configuration where the inner rotor is positioned inside the outer rotor, creating a compact concentric structure. This nesting allows the motor to generate high torque through the magnetic interaction between the two rotors while occupying minimal radial space, effectively doubling the magnetic interaction surface area within a compact footprint.
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 design reduces moment of inertia, maintains high torque, and enhances efficiency by operating closer to nominal speed, minimizing size and cost increases while optimizing energy use.
Implementation Method 1
a stator, secured to the frame, a rotor, arranged in the stator and comprising a cylindrical part... permanent magnets, arranged on the outer peripheral wall of the cylindrical part... each permanent magnet comprising a respective outer surface, the outer surfaces facing the winding teeth
Data Source
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AI summary
The machine (9) comprises a rotary electric motor, a crank, a driving lever and a driving rod. The stator (23) of the motor comprises winding laminations (33), extending radially between a stator outer diameter (D23e) and a stator inner diameter (D23i), and electrical windings (39). The rotor (29) of the motor comprises a rotor shaft (51), centered on a main axis (A1), surrounded by a cylindrical portion (53) of the rotor and secured to the cylindrical portion and the crank, and permanent magnets (57). A ratio of the external stator diameter (D23e) to a length (L53) of the cylindrical part (53), measured parallel to the main axis without exceeding the permanent magnets, is between 2.0 and 4.0, preferably between 2.5 and 3.5, more preferably between 2.8 and 3.2.