Torque Motor Press Drive with Direct Shaft Integration
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Solution Overview
Problem
Current press drive devices for presses have low energy efficiency, with only about 10% of consumed energy converted into workpiece formation, while the rest is lost as heat due to friction and conversion losses, and they lack high dynamics in ram movement.
Innovation Solution
A press drive device featuring a torque motor with a rotor hub directly connected to a drive shaft, mounted via minimal bearing points to reduce friction and gear-related losses, and utilizing a toggle lever mechanism for high torque and acceleration transmission, achieving compact design and efficient energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional press drive devices with multiple components and gear modules are used, then the press can achieve sufficient torque and force, but energy efficiency is low with only about 10% of consumed energy converted into workpiece formation
Solution Approach 1:
The patent combines the drive motor, drive shaft, and connecting rod bearing into a single integrated press drive device. The motor is arranged with its rotor hub forming part of the drive shaft, eliminating the need for separate gear modules and intermediate transmission components. This merging of components reduces the number of interfaces and connection points where energy losses occur, thereby improving overall energy efficiency while maintaining the necessary torque and force transmission capabilities.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components such as gear modules, planetary gears, and separate mounting bearings from the drive system. By removing these components that contribute to friction and conversion losses, the system achieves higher energy efficiency. The essential functions are retained through the direct connection of the motor rotor hub to the drive shaft, which provides sufficient torque transmission without the need for additional transmission elements.
2Loss of energy
If conventional press drive devices with multiple bearings and gear modules are used, then the press structure is stable, but friction losses and conversion losses are high
Solution Approach 1:
The patent removes unnecessary intermediate bearings and gear modules from the drive system. Only the essential mounting bearings at the ends of the drive shaft are retained, eliminating multiple intermediate bearing points that would generate friction losses. This reduction in the number of bearing interfaces directly decreases friction losses while the retained bearings maintain the structural stability and rotational support of the drive shaft.
Solution Approach 2:
The motor rotor hub is merged with the drive shaft structure, eliminating the need for separate intermediate connection components. This integration reduces the number of interfaces where friction occurs, as there are no additional mounting bearings or gear interfaces between the motor and drive shaft. The structural stability is maintained through this integrated design while minimizing friction losses at the remaining essential bearing points.
3Loss of energy
If a compact press drive device with minimal bearing points is used, then energy efficiency is improved, but the ability to transmit high torque may be compromised
Solution Approach 1:
The motor rotor hub is merged with the drive shaft to form an integrated torque transmission structure. This direct connection eliminates intermediate gear modules and planetary gears that would cause conversion losses, allowing high torque to be transmitted efficiently from the motor to the connecting rod bearing. The integrated design ensures that the full torque capability of the motor is transmitted without losses through gear interfaces.
Solution Approach 2:
The patent concentrates the torque transmission function at the essential mounting bearings and the integrated rotor hub-drive shaft connection, rather than distributing it through multiple intermediate components. This localized torque transmission path minimizes the number of interfaces where conversion losses occur, while the essential bearing points are designed to handle the high torque loads effectively.
4Productivity
If the press drive device reaches full speed quickly with high dynamics, then productivity is improved, but friction and conversion losses increase
Solution Approach 1:
The patent removes intermediate gear modules and planetary gears that would cause conversion losses during rapid acceleration and deceleration. By eliminating these intermediate transmission components, the system achieves high dynamics with the ram reaching full speed quickly, while minimizing the conversion losses that would occur in gear interfaces during dynamic operation.
Solution Approach 2:
The direct integration of the motor rotor hub with the drive shaft creates an efficient torque transmission path that minimizes energy losses during rapid changes in motion. This merged structure allows high dynamics and quick acceleration to full speed while reducing the friction and conversion losses that would occur in multi-component transmission systems during dynamic operation.
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 results in a press drive system with high energy efficiency and dynamic ram movement, reaching full speed in less than 40 milliseconds, with minimized friction losses and low mass moments of inertia, enhancing the overall performance of the press.
Implementation Method 1
at least one electric drive motor, in particular a torque motor, with a stator and a rotor
Implementation Method 2
The drive shaft is mounted via at least two bearing devices at two bearing points exclusively
Implementation Method 3
a connecting rod bearing that is eccentric to the shaft axis. The drive end of the connecting rod is mounted on the connecting rod bearing
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a press drive device (21) for a press (10), comprising a connecting rod (49) that has an input end (48) and an output end (50). The output end (50) is preferably coupled to a toggle joint (55) of a toggle mechanism (51). A drive shaft (35) is mounted at a first mounting point (36) using a first bearing mechanism (37) and at a second mounting point (39) using a second bearing mechanism (40) so as to be rotatable about a shaft axis W. Between the two bearing points (36, 39), the drive shaft (35) includes a connecting rod bearing (46) that is eccentrical in relation to the shaft axis W. The input end (48) of the connecting rod (49) is mounted on the connecting rod bearing. An electric driving motor (30), preferably a torque motor, comprises a stator (35) that is connected in a rotationally fixed manner to a frame (12) of the press (10). A rotor (66) supported by a rotor hub (67) is arranged radially within the stator (65). The rotor hub (67) is connected in rotationally fixed manner directly to the drive shaft without using any step-up or step-down gear. The rotor (66) and the rotor hub (67) of the driving motor (30) as well as the drive shaft (35) are mounted exclusively at the first bearing point (36) and the second bearing point (39). There are no additional bearing points.