Universal Motor Brake Kit for Compact Production
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Solution Overview
Problem
Existing electric motor production methods are inefficient and lack cost-effectiveness, particularly in ensuring safety and versatility across different motor types, as they require a large number of parts and do not easily accommodate various functionalities and braking systems.
Innovation Solution
A kit and method for producing electric motors that utilize a pre-completed brake system, where a single brake design can be used across multiple motor types, including asynchronous and synchronous motors, with the brake being electromagnetically actuable and integrated into the motor housing, allowing for increased safety and compact structure through shared components and sealed connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional production methods are used for electric motors, then each motor type requires separate parts and assembly processes, but this increases production costs and reduces efficiency
Solution Approach 1:
The brake assembly is designed as a universal component that can be used across multiple motor types (asynchronous and synchronous motors). The same brake assembly with bearing plate integration can be accommodated in different motor housings, eliminating the need for motor-type-specific brake parts and reducing overall part complexity while maintaining productivity benefits.
2Adaptability or versatility
If separate brake systems are used for each motor type, then motor-specific braking functionality is achieved, but this increases inventory requirements and logistical complexity
Solution Approach 1:
A single universal brake assembly design serves multiple motor types including both asynchronous and synchronous motors. The brake assembly integrates with the bearing plate and can be accommodated in different motor housings through standardized mounting interfaces, allowing one brake design to replace multiple motor-specific brake designs, thereby reducing inventory requirements.
3Reliability
If brakes are assembled during motor production, then integration is achieved, but this prevents functional checks before assembly and reduces quality control
Solution Approach 1:
The brake assembly is pre-completed as a separate unit before integration into the motor. This preliminary assembly allows functional checks and quality control measures to be performed on the brake system independently, ensuring proper operation before the brake is installed in the motor, thereby improving reliability without significantly complicating the overall manufacturing process.
4Volume of moving object
If compact motor design is pursued, then space efficiency is improved, but this makes it difficult to accommodate additional functionalities like multiple brakes
Solution Approach 1:
The brake assembly is merged with the bearing plate structure, where the bearing plate serves dual functions as both a structural support component and a braking surface. This integration allows the brake system to be accommodated within the existing motor housing volume without requiring additional space, while still enabling the addition of multiple brake functionalities through the same integrated structure.
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 approach enables the production of a variety of motors with a small number of parts, ensuring safety by allowing the brake to function in case of power failure and simplifying production by allowing functional checks before assembly, while also reducing logistical complexity and increasing safety through redundant braking systems.
Implementation Method 1
the first or second add-on unit comprises at least one second brake, the second brake being attachable to the housing of the motor
Implementation Method 2
with the first brake being designed as an electromagnetically actuable spring-loaded brake
Implementation Method 3
an electromagnetically actuable friction brake
Data Source
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AI summary
The invention relates to a kit for the production of different electric motors of a series of electric motors and to the method of production, said kit comprising - a first brake, - a first and a second bearing plate, - a first and a second housing part, - a first and a second add-on unit. According to the invention, the first housing part can be connected to the first bearing plate, in particular by a screw connection, thereby forming a housing for a first motor, wherein the second housing part can be connected to the second bearing plate, in particular by a screw connection, thereby forming a housing for a second motor. The first brake can be received optionally in the first or the second bearing plate so that the respective bearing plate encloses the first brake to form a housing, and the rotor shaft of the motor can be mounted in a bearing received by the bearing plate, the housing enclosing the stator windings of the motor and being composed of housing parts, in particular by means of sealed screw connections between the respective bearing plate and the respective housing part.