Stepper Motor Transmission with Grooved Shaft for Higher Torque
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Solution Overview
Problem
Stepping motors face issues with broken teeth and dislodged output shafts due to low torque, leading to instability and durability problems.
Innovation Solution
A transmission mechanism with an output shaft featuring evenly distributed grooves and an output gear with matching arc-shaped bumps, along with multiple transmission gear sets, enhances engagement reliability and increases torque by decelerating the rotation speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the output torque of the stepping motor is increased to prevent slipping, then the torque output is improved, but the structure becomes more complex and the cost increases
Solution Approach 1:
The transmission mechanism is segmented into multiple independent gear sets (first, second, and third gear sets) with distinct functions. Each gear set handles specific transmission tasks, allowing the system to achieve high torque output through staged gear reduction rather than a single complex mechanism. This segmentation enables modular design and simplifies manufacturing while maintaining the ability to prevent slipping.
Solution Approach 2:
The patent introduces a multi-dimensional transmission approach by arranging gear sets both radially (along the circumferential direction) and axially (along the input shaft length). This spatial arrangement allows torque multiplication across multiple dimensions, achieving high output torque without requiring a single overly complex transmission path.
2Reliability
If the output shaft and output gear engagement is strengthened to prevent broken teeth and dislodgement, then the reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent employs arc-shaped grooves on the output shaft and corresponding arc-shaped bumps on the output gear instead of straight or pointed features. This curvature design distributes contact stresses more evenly across the engagement surfaces, reducing peak stresses that would require extremely tight manufacturing tolerances. The arc shape provides natural stress distribution and smoother engagement, enhancing reliability while being more tolerant of manufacturing variations.
Solution Approach 2:
The transmission mechanism incorporates multiple gear sets that progressively reduce speed and multiply torque before reaching the output gear. This staged approach cushions the engagement loads by distributing them across multiple transmission stages rather than applying full torque directly to a single gear engagement. The intermediate gear sets act as buffers, reducing the instantaneous stress on the output shaft and gear teeth.
3Force
If multiple transmission gear sets are added to increase torque, then the output torque is improved, but the device complexity increases
Solution Approach 1:
Each transmission gear set is designed to perform multiple functions: speed reduction, torque multiplication, and axial positioning. The gear sets share common structural elements and mounting arrangements, allowing them to be manufactured and assembled using similar processes. This multi-functionality reduces the overall complexity compared to having separate specialized components for each function.
Solution Approach 2:
The transmission gear sets are arranged in a nested configuration where the second gear set is positioned within the space defined by the first gear set, and the third gear set is positioned within the space defined by the second gear set. This nesting approach maximizes space utilization and allows multiple gear sets to be integrated into a compact transmission mechanism without proportionally increasing the overall device footprint or complexity.
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 stabilizes the stepping motor operation, prevents issues like broken teeth and dislodged shafts, and increases torque, resulting in a more durable and stable motor performance.
Implementation Method 1
an output shaft provided with a plurality of grooves, wherein the plurality of grooves are evenly distributed on a circumferential surface of the output shaft; an output gear installed on the output shaft, wherein the output gear is provided with a plurality of bumps, and the bumps are matched with the respective grooves
Implementation Method 2
a plurality of transmission gear sets for transmitting a power, wherein the plurality of transmission gear sets are connected to the input shaft and the output gear
Data Source
AI summary
A transmission mechanism of stepping motor, a stepping motor having the transmission mechanism of stepping motor and a driving mechanism having the stepping motor are disclosed. The transmission mechanism of stepping motor includes an input shaft; an output shaft provided with a plurality of grooves, where the plurality of grooves are evenly distributed on a circumferential surface of the output shaft; an output gear installed on the output shaft, where the output gear is provided with a plurality of bumps, and the bumps are matched with the respective grooves; and a plurality of transmission gear sets for transmitting a power, the plurality of transmission gear sets are connected to the input shaft and the output gear.