Stacked Motor Drive Assembly for High Power in Tight Spaces

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Solution Overview

Problem

Existing drive mechanisms face challenges in generating significant power while being compact, as they often require large and expensive electric motors, which are cumbersome and unsuitable for spatially limited environments.

Innovation Solution

A stacked motor assembly comprising two vertically spaced electric motors with rotatable driver members and a flexible drive member that couples them to an output shaft, allowing for efficient power transmission and compact design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a single large electric motor is used to generate significant power, then power output is improved, but device volume and weight increase

Engineering Contradiction:
Improvepower outputVSAvoidmotor volume
Core Design Contradiction:
PowerVSVolume of moving object

Solution Approach 1:

The patent divides a single large motor into multiple smaller motors (first motor and second motor) that are stacked vertically. Each motor has its own rotor and stator assembly, and they work together to provide the total required power output. This segmentation allows the system to achieve significant power while maintaining a compact footprint, as the combined volume of multiple small motors is less than a single large motor providing equivalent power.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent transitions from a horizontal arrangement of motor components to a vertical stacking configuration. The first and second motors are arranged vertically with their rotors stacked along the vertical axis, and the drive belt wraps around both rotors in a vertical plane. This dimensional change allows efficient use of vertical space while maintaining compact horizontal footprint, resolving the contradiction between power output and device volume.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Power

If a single large electric motor is used to generate significant power, then power output is improved, but device cost increases

Engineering Contradiction:
Improvepower outputVSAvoidmanufacturing cost
Core Design Contradiction:
PowerVSEase of manufacture

Solution Approach 1:

The patent segments the power generation function into multiple smaller motors, each with standard化的 components (stators, rotors, windings). These modular units can be manufactured using standard production processes and then assembled together, reducing tooling costs and enabling economies of scale. The segmented approach allows for easier manufacturing and lower overall cost compared to producing a single custom large motor.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent changes the operational parameters by using multiple motors operating in parallel rather than one motor. Each motor operates at optimized parameters for its size, and their combined output achieves the required total power. This parameter change enables the use of smaller, more efficient motors that can be manufactured more cost-effectively while meeting the overall power requirements.

Inventive Principle:
Principle #35Parameter changes

3Power

If a single large electric motor is used to generate significant power, then power output is improved, but device complexity increases

Engineering Contradiction:
Improvepower outputVSAvoidmechanism complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent employs a universal drive belt mechanism that serves multiple functions: it transmits torque from both the first and second motors to the common output shaft, and it integrates the power output of both motors into a single rotational motion. This multi-functional belt system simplifies the overall mechanism by providing a single torque transmission path that handles the combined output of both motors, reducing the need for additional gears, shafts, or coupling mechanisms.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 enables the generation of significant power in spatially limited environments, making it suitable for applications requiring substantial power without the need for large motors, thus optimizing both power output and spatial efficiency.

Implementation Method 1

a flexible drive member rotatably coupling the first rotatable driver member, the second rotatable driver member, and the output shaft together such that rotation of the first rotatable drive member by the first motor and rotation of the second rotatable driver member by the second motor impart rotational torque to the output shaft

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentUS20240084878A1Drive Mechanism
Publication Date: 2024.03.14 HERKULES EQUIPMENT CORP
  • US20240084878A1 patent drawing
  • US20240084878A1 patent drawing
  • US20240084878A1 patent drawing

AI summary

A drive mechanism includes a stacked motor assembly. The stacked motor assembly includes a first motor, a first rotatable driver member rotationally fixed to the first motor, a second motor vertically spaced from the first motor, and a second rotatable driver member rotationally fixed to the second motor. The drive mechanism also includes an output shaft spaced from the first motor and the second motor and a flexible drive member rotatably coupling the first rotatable driver member, the second rotatable driver member, and the output shaft together such that rotation of the first rotatable drive member by the first motor and rotation of the second rotatable driver member by the second motor impart rotational torque to the output shaft. The drive mechanism further includes an output belt fixed to the output shaft and configured to be wound about the output shaft upon rotation of the output shaft.