Drive Optimization for Robotic Lawnmowers
The supplier of a drive system for robotic mowers was forced to implement a technological and cost-related revision of its product. Our customer wanted to expand its own capabilities in the value chain through forward integration in order to be able to offer its own drive consisting of motor, gearbox and housing parts. As the customer has a high level of expertise in mechanical manufacturing, the aim was to produce the motor-gearbox combination in-house.
Brief
Our task was to design and build a customized BLDC motor to the given specification and product requirements. On the one hand, the functional requirements had to be taken into account, but on the other hand, the safety-relevant functions of the drive in the later product also had to be considered. In addition, a selection of suppliers was made from the outset to ensure a high degree of transparency.
Challenge
The biggest challenge for the integration of the motor was the low application-related speed and the high torque. This requirement is often realized with a 2nd gear stage, but this was not possible in the target project due to the cost pressure. For this reason, a special and adapted circuit was selected for the commutation of the motor. After a FluidFEM simulation, the operating point of the motor was optimized for the main application speed. The motor was prototyped on the basis of an existing drive and tested in the application.
First, a parameterizable model of a BLDC motor suitable in terms of installation space and type was created. Simulations of the magnetic flux were carried out on the basis of the model, taking into account the possible and eligible commutations. In a second step, these results were used to build and measure a prototype motor. Through permanent iterations, the partly divergent parameters were adjusted to an optimal solution.
Results
Today, the customer is able to purchase electric motors or assemblies for electric motors independently and integrate them into the application. This also enables the customer to pass on the increasing cost pressure to a large number of suppliers of certain assemblies. In addition, the management can make improved and quantity-dependent "make or buy" decisions and the customer is now able to procure electric motors or assemblies for electric motors independently and integrate them into the application. This also enables the customer to pass on the increasing cost pressure to a large number of suppliers of certain assemblies. In addition, management can make improved and quantity-dependent "make or buy" decisions.
Roller Test Bench - Your Advantages at a Glance
- Customized test bench solutions, tailored to your requirements and needs.
- Flexible systems make it easy to adapt the roller test bench measurements to a wide range of vehicle types and models.
- A wide spectrum of tests from standardized procedures such as the R200 range test for e-bikes to individually adapted tests.
- Fast and efficient test execution thanks to our flexible clamping system.
- Innovation and technology leadership as well as comprehensive expertise in the latest test bench technology.
- Simulation of real riding conditions on the Hil test benches.
- Protection against wear and safety risks as vehicles are tested stationary in our test center.
- Standard-compliant tests, for example in accordance with eKFV for electric vehicles.
Contact us!
Describe the requirements for your project, the test bench or the measurements without obligation.
Our experts will check your request and contact you.
EMEC-PROTOTYPING GmbH
Dölzschener Straße 47
01159 Dresden, Germany
Phone: +49 (0) 35143873280
Fax: +49 (0) 35142442586
