Motor Mounting Research Articles

PRINTING A «BRACKET» TYPE PART FOR AN ENERGY-EFFICIENT CAR

Additive technologies play an important role in modern automotive design and manufacturing, with their applications expanding every year. Originally used primarily for prototyping and mock-up production, 3D printing is now increasingly being used to manufacture key automotive components, with some companies offering fully 3D printed vehicles. This article analyzes the possibilities of printing load-bearing structures and the design of a key element - the electric motor mounting bracket for the TOQ car prototype. TOQ Prototype EV is an energy-efficient electric vehicle prototype being developed by the SU Racing Team from Satbayev University. The goal of the project is to create an ultra-light, durable, energy-efficient prototype vehicle with a long range of 1 kWh of energy. The use of new materials and additive technologies opens up the possibility of creating a variety of combinations, both for the production of parts with increased strength and for the use of advanced materials in the interior of the cabin. The process of prototyping an energy-efficient electric vehicle using additive manufacturing illustrates an innovative approach to improving energy efficiency and reducing energy consumption. This article details the process of designing an electric motor bracket using generative design and additive manufacturing. The study aims to evaluate the feasibility of 3D printing the load-bearing and critical elements of an electric vehicle prototype, as well as to simulate the loads when operating an electric motor with a peak power of 2 kW. Keywords: Mechanical engineering, automotive industry, additive manufacturing, 3D printing, industry 4.0, racing car, energy efficiency.

Design and Development of Quadcopter’s Frame

The purpose of this research is to obtain a design and prototype of quadcopter’s frame, which be developed further as a quadcopter that capable of carrying payload of 1.5 kg with flight time of more than 20 minutes. The design begins with estimating the values of Maximum Take-Off Weight (MTOW), required thrust, propeller dimensions, and wheelbase dimensions of the quadcopter. The results show the MTOW of the quadcopter was 5 kg, with each motor requiring of 2.5 kg of thrust per arm. The wheelbase dimension was 790 mm, and the propeller diameter of 17 inches. A wheelbase dimension was utilized to develop three conceptual frame designs for the quadcopter. The three conceptual designs were selected using a decision matrix table. The selected design was calculated for its structural strength by applying a load of 2.5 kg on each motor mounting. The results show the maximum stress value of 21.17 MPa, the maximum deflection of 3.5 mm, and safety factor of 22.44. Then, the prototype of quadcopter’s frame was manufactured. Therefore, the producing of prototype was measured the mass and deflection. Based on the measurements conducted, the quadcopter frame has an actual mass of 595 grams and a maximum deflection of 3.7 mm. The actual deflection value and the actual mass are close to the deflection and mass obtained from the calculation.

6-degree-of-freedom Motor mounting characteristic for high frequency Solid-borne of Battery Electric Vehicles

Battery Electric Vehicles (BEVs) are required high level of noise / vibration performance. In the case of Internal Combustion Engine Vehicles (ICEVs), solid-borne noise has been considered mainly up to 1 kHz. For BEVs, the frequency range of solid-borne noise is higher because of the electric powertrain and other mechatronic on board. The motor mounting has internal resonances in the high frequency range that can cause noise issue in prototype vehicles, leading to vehicle development rework. In this paper, we introduce the need to deal with 6 degrees of freedom (DOF) characteristics in NV development for BEVs and propose a new measurement method that makes it possible to measure 6-DOF characteristics. Using this approach, this makes it possible to design the high frequency noise at the planning phase before vehicle prototyping, which is expected to improve development efficiency.

Performance analysis on the structure of the bracket mounting for hybrid converter kit: Finite-element approach

Abstract An electric motor mounting bracket is used in electric vehicles, especially hybrid ones using a parallel hybrid configuration. This study aims to analyze the strength and performance of the initial design and topology optimized design. This study uses the finite-element method (FEM) in the bracket design modeling by applying topology optimization. The topology optimization results show a mass reduction of 50% from the initial design mass. In the case of static loading, the results of optimized design 2 have a stress of 142.19 MPa and a safety factor of 3.09. While optimized design 1 has a stress of 313.8 MPa and a safety factor of 1.4. In terms of dynamic loading, the initial design, optimized design 1, and optimized design 2 have the first natural frequency, which is higher than the operating frequency of the electric motor, respectively, 100.49, 69.043, and 74.864 Hz. Optimized design 1 has the lowest natural frequency and the highest amplitude compared to the initial design, and optimized design 2 has lower damping characteristics. The study results conclude that optimized design 2 is superior in static and dynamic loading.

Multi System Level Driving Scenarious Based Topology Optimization of Bracket Design for 2 DoF Vehicle Simulator

This article presents a topology optimization of the motor mounting bracket in a 2-degree-of-freedom (2 DoF) vehicle simulator that is enhanced by the driving scenari-os. Firstly, a 14 DoF passenger reference application model is determined in the Sim-ulink environment. Then, common driving scenarios (Constant Radius, Double Lane Change, Fishhook, Increasing Steer, Sine with Dwell and Swept Sine) are run on 14 DoF vehicle models to test the dynamic performance of the vehicle. During the anal-ysis, accelerations in the XYZ axes are logged, and the minimum and maximum ac-celeration values on each axis are grouped separately for each driving scenario. Next, the concept design of 2 DoF vehicle simulators is created. The obtained accelerations from the driving scenarios are then run on 2 DoF vehicle simulator in the Solidworks simulation environment, and stress and deformation on the 2 DoF vehicle simulator are analyzed. During this analysis, linear actuator and axis forces are calculated ac-cording to the reaction forces on the vehicle simulator. Under the determined axial forces, the brackets are subjected to topology optimization. The obtained generative design of the bracket is reshaped by post-processing for sustainable production. The shape-optimized bracket is run again on the 2 DoF vehicle simulator with the ob-tained acceleration values from the driving scenarios, and the study is completed by performing stress and deformation analysis.

Analysis of Elliptical Shape Composite Spring Mounting

A motor mounting is an application segment that interfaces the motor section to the machine edge of unit. Motor is connected with the machine body by a few mounts, which are significant for smooth activity of use. A motor mount is utilized to confine body from vibration during working and motor created commotion varying sorts of mounts are use in apparatus and vehicles. Varying kinds of mounts are use in apparatus and vehicles. Elastomeric mount are minimal effort and least complex kind of mounts, they smother motor power/torque and vibrations through cooling. An elastomeric mount can give the predetermined solidness to the reverberation control and stun retention; however elastic damping in low frequencies isn't adequate. Circular shape spring mounting might be a vibration and stun isolator planned explicitly for back mounted motor applications and is reasonable to watch the apparatus client against stun and vibration in back held application like motor sprayers, trimmers and expresses. Material chose for spring is SS304 (from 0.3 ~ 0.8mm) thickness and polymer material as support in spring. The two materials are resistant to consumption and work productively under wide choice of temperature. Essential structure utilizes high pliable hardened stainless-steel SS304 framed leaves on all sides with the polymer sheet of 6mm thickness. Unigraphics Nx-8.0 is used for 3D modeling and Analysis of component and meshing is completed with the help of Ansys work Bench16.0.

Design Right Once for Additive Manufacturing

Additive Manufacturing (AM) has been widely considered a key factor for innovative design. However, the utilization of AM has not been as high as expected, although the technology offers key innovative design capabilities, weight reduction, parts count and assembly consolidation as well as material saving. This low utilization is attributed to the lack of AM understanding, mature CAE/CAM software tools addressing AM specific issues such as design support structure generation and removal, residual stresses, surface quality. In most cases, Design for AM (DfAM) is a crucial requisite for a “Design Right Once” approach. Such an approach is shown in the current study using three parts as example: an arthropod’s leg, a gearshift drum and an electric motor mounting frame. The implementation of geometrical conformal lattice structures and lattices with variable density are discussed. A structured design approach is presented and design dilemmas are solved in terms of a DfAM approach. Primary design optimizations are evaluated. Weight reduction is considered throughout the design and free form surfaces are being used. “Freedom to Design” principle is also portrayed and assembly parts consolidation occurs as a natural process of DfAM in comparison with previous design practices. It is concluded that, even from the primary design phase the design engineer can reveal his creativity because of the absence of constraints set by the traditional manufacturing technologies.

Quiet rim driven ventilation fan design

Auxiliary ventilation fans are commonly used as a form of temperature and humidity control of working environments. However, they often generate high noise levels that cause permanent hearing impairment from prolonged exposure. Dominant noise sources from ventilation fans such as noise due to the aerodynamic interaction of the fan with the struts to support the hub motor and the blade-duct tip gap can be eliminated using a rim driven fan. However, tones from blade steady loading and thickness and the broadband airfoil self-noise of the fan are not eliminated. This noise is proportional to the 4-6th power of the tip speed. Hence, the approach here is to design a ring driven ventilation fan that reduces the fan tip speed while optimizing the blade profile to retain aerodynamic performance. The fan design has been 3D printed and implemented using a motor mounting system to validate the predicted performance. The motor mounting system integrates the fan design, a bell mouth shaped duct and a brushless DC motor. The experiments show good agreement with the predicted mechanical power, axial flow, and radiated noise over a range of speeds. Results suggest that a ring driven fan reduces noise while maintaining aerodynamic performance.

Investigative Study of Vibration Induced Stress Analysis on Motor Mounting Lugs

Investigative Study of Vibration Induced Stress Analysis on Motor Mounting Lugs

생체 모방 로봇을 이용한 관로 모니터링 시스템의 구현

We present a pipeline monitoring system based on bio-memetic robot in this paper. A bio-memetic robot exploring pipelines measures temperature, humidity, and vibration. The principal function of pipeline monitoring robot for the exploring pipelines is to recognize the shape of pipelines. We use infrared distance sensor to recognize the shape of pipelines and potentiometer to measure the angle of motor mounting infrared distance sensor. For the shape recognition of pipelines, the number of detected pipelines is used during only one scanning of distance. Three fuzzy classifiers are used for the number of detected pipelines, and the classifying results are presented in this paper.

Two piece blower housing with vibration absorbing bottom piece and mounting flanges

A blower housing having a resilient bottom piece and a rigid top piece assembling with the bottom piece is provided. The top piece includes a plurality of depending legs which are urged against a matching plurality of flanges formed in the resilient bottom piece to cushion mount the top piece to a furnace or the like. A plurality of mechanical fasteners such as screws or the like extend through a plurality of lugs on the top piece and through the flanges to urge the depending legs against the flanges and the furnace. Through this construction, a generally rigid connection between the motor mounting plate and the furnace is achieved while providing the sound and vibration attenuation of a resilient housing.

Installation effects on fan acoustic and aerodynamic performance

Sound power measurements were performed on an upright vacuum cleaner in order to identify predominant noise generating mechanisms and to recommend corrective noise control modifications that would cause no increase in production costs. These modifications were then implemented and their effectiveness quantified. In general, the noise radiated by the vacuum cleaner is dominated by aerodynamic sources. Aerodynamic interactions occur between the electric motor cooling fan and nearby motor mounting fixtures resulting in intense tones at blade rate and harmonic frequencies. These tones are reduced by as much as 25 dB in level, to the broadband sound power level of the unit, by eliminating certain flow obstructions, and mounting the motor in an alternative fashion. Motor cooling performance is also dramatically improved by the new mounting arrangement resulting in a 26 °C reduction in steady-state operating temperature. © 1999 Institute of Noise Control Engineering. †S0736-2501„99...00101-0‡

Noise isolating motor mounting system for a canister vacuum cleaner

An arrangement for mounting a motor blower assembly (24) in a canister vacuum cleaner uses a pair of resilient rubber rings (36, 42), one each on the front and rear of the assembly, to isolate the motor from the vacuum cleaner housing (12). The front ring (36) goes over the front of the fan casing (28) and is trapped within the housing (12), while the rear of the motor (26) has attached thereto an adaptor (40) which fits within the complementarily shaped rear rubber ring (42). This rear rubber ring (42) in turn fits within a complementarily shaped motor support (44), which is attached to a support abutment (54) within the housing (12). In order to accommodate different size motors within the same housing and utilize the same mounting components, the support abutment (54) is pre-drilled at various locations (58) to accommodate the different size motors. Thus, the only fixed attachment to the housing (12) is the rear support (44), which is isolated from the motor blower assembly (24) by the rear rubber ring (42).

The effect of magnet geometry on electric motor vibration

A principal source of vibration in permanent magnet (PM) motors and generators is the traveling forces on the stator induced by the rotating permanent magnets. These forces are transmitted through the stator and to the surrounding system. The magnetic forces were calculated from the flux density by finite element methods (FEMs). The dynamic reactions at the motor mounting points, which provide the forcing function to the base system, were also calculated by FEMs. The vibration characteristics and the transmissibility of each frequency component were investigated using Fourier decomposition of the traveling magnetic force. The results showed that for a radially centered rotor the frequency components of the magnetic force were integer multiples of the rotor speed multiplied by the number of magnetic poles. Higher harmonics were more difficult to transmit, except when stator structure resonance occurred. The edge shape of the PM determined the shape of the magnetic force and the magnitude of the frequency components. By proper shaping of the magnetic edges, the composition of the magnetic force spectrum can be assigned to higher frequencies, reducing the overall transmission to the base system.< <ETX xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">&gt;</ETX>

Space Sled--a device for the investigation of the physiological effects of weightlessness.

Space Sled is a device for providing controlled linear acceleration stimuli in the microgravity environment of orbital flight. The scientific objectives of the experiments which used Space Sled on the D-1 Spacelab mission were to study aspects of otolith organ (that is, that part of the inner ear which transduces linear accelerations) function and adaptation in weightlessness. Space Sled comprises electrical and mechanical sub-systems. The latter is made up of a carriage running on twin rails that are fixed to the floor of Spacelab. The assembly is 6 m long with a working section of 3.5 m. The seat accommodating the test subject can be mounted on the carriage in any of three orthogonal positions. The carriage is coupled by a flexible steel cable to a servo-controlled electric motor which is capable of producing a peak acceleration of 2 m/s2 and peak velocity of 2.4 m/s. In the event of failure of comprehensive safety circuits in the electrical sub-system, a mechanical snubber, of crushable honeycomb construction, limits the deceleration to 20 m/s2. Mechanical structures providing carriage guidance, Sled/Spacelab interfaces, carriage latching, motor mounting and cable tensioning are detailed in the paper.

Torsional vibration isolating motor mounting system, mounting arrangement, assemblies including the same

Motor vibration isolating arrangements and systems using such arrangements are disclosed. In preferred arrangements, leaf spring mounting arms have low torsional spring constants and yet strength to withstand shipping and handling loads. The mounting member spring constants for axial, radial and tilting vibration modes are selected in specific forms so that the characteristic vibration transmissibility ratios for these modes are each close to unity, but so that torsional mode vibration transmissibility is substantially less than unity. In particularly preferred arrangements, sheet steel having a martensitic grain structure is utilized. In some forms, the motor shell constitutes one weldable member and a holding plate is weldable. The spring material is protected by heat sinking from being softening and weakened by conventional welding processes. The heat sinking members also contribute to a very strong fastening scheme.

Torsional vibration isolating motor mounting arrangement and method of making same

Motor mounting system is designed so that the torsional mode resonant or natural frequency is less than twice the frequency of the motor power supply divided by the square root of two (√2). The illustrated mounting arrangements are "soft" with respect to torsional mode vibrations, and yet are "stiff" with respect to axial and tilting mode vibrations. In one arrangement, lugs are formed preferably from a tough and strong sheet or strip material that is thicker and substantially stronger and stiffer (even in the radial vibration mode) than would usually be desirable from a torsional vibration isolation standpoint, but means are provided for promoting flexure in the vicinity of the parts of the lugs that will be subject to the most flexure or deflection. These flexure promoting means may be in the form of tuning apertures formed along a preselected, longitudinally extending neutral axis of each lug so that the strength of the lug will not be objectionably compromised for axial loading conditionss. It is preferred to select the tuning means so that the cumulative effective spring constant (in pound-inches per radian) of the mounting lugs will be less than the quantity (2.84× Ip×10 5 ), where Ip is the polar moment of inertia measured in pound-inches-seconds 2 . Also illustrated are mounting band members and torsionally flexible arms that interfit one with another in a slotted interrelationship. Ends of the arms are folded under a band member so that the ends of the arms are securely trapped by the band member against the outer peripheral surface of the motor. This technique assures that the motor will remain supported by the band member and arms, and minimizes the degree of weld or other fastener strength that would otherwise have to be provided between the arms and motor.

Sexual dimorphism in the motor mounting pattern of the New Zealand white rabbit: Steroid regulation of vigor and rhythmicity of pelvic thrusting

The motor mounting patterns of male and female New Zealand white rabbits were analyzed by means of an accelerometric technique and frequency analysis. Clear behavioral dimorphism was noted in the motor mounting pattern. Pelvic thrusting by males was periodic while that performed by females lacked rhythmicity. Thrusting in males was more vigorous than in females. Ovariectomy markedly decreased the incidence of mounting behavior. Testosterone propionate (TP, 5 mg daily for 1 month), restored mounting in all ovariectomized rabbits. TP stimulated the vigor of thrusting and induced a rhythmic mounting pattern in many cases similar to that displayed by intact male rabbits, i.e., thrusting frequency 13–16 per second. Estradiol benzoate (10 μg daily for 1 month), elicited mounting in three of the seven rabbits tested. Pelvic thrusting in these rabbits was often highly synchronous showing a frequency higher (18 to 21 thrusts per second) than that displayed by male rabbits. The results suggest the following conclusions: (a) the behavioral dimorphism in mounting observed in rabbits is due to variations in the secretion of sex steroids by the adult gonads rather than to differences in the organization of the neural substrate of mounting; (b) gonadal steroids influence directly or indirectly the neural structures involved in some characteristics of pelvic thrusting, i.e., rhythmicity and vigor.

Hydraulically damped rubber motor mounting

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Torsional vibration isolating motor mounting arrangement and method of making the same

Torsional vibration isolating motor mounting arrangement and method of making the same