Direct-drive mechanism

A direct-drive mechanism is a mechanism design where the force or torque from a prime mover is transmitted directly to the effector device (such as the drive wheels of a vehicle) without involving any intermediate couplings such as a gear train or a belt.[1][2][3][4]

History

In the late 19th century and early 20th century, some of the earliest locomotives and cars used direct drive transmissions at higher speeds.[5][6] Direct-drive mechanisms for industrial arms began to be possible in the 1980s, with the use of rare-earth magnetic materials.[1] The first direct-drive arm was built in 1981 at Carnegie Mellon University.[7] Today the most commonly used magnets are neodymium magnets.[8]

Design

Direct-drive systems are characterized by smooth torque transmission, and nearly-zero backlash.[9][10][11] The main benefits of a direct-drive system are increased efficiency (due to reduced power losses from the drivetrain components) and being a simpler design with fewer moving parts. Major benefits also include the ability to deliver high torque over a wide range of speeds, fast response, precise positioning, and low inertia.[12][13]

The main drawback is that a special type of electric motor is often needed to provide high torque outputs at low rpm. Compared with a multi-speed transmission, the motor is usually operating in its optimal power band for a smaller range of output speeds for the system (e.g., road speeds in the case of a motor vehicle).

Direct-drive mechanisms also need a more precise control mechanism. High-speed motors with speed reduction have relatively high inertia, which helps smooth the output motion. Most motors exhibit positional torque ripple known as cogging torque. In high-speed motors, this effect is usually negligible, as the frequency at which it occurs is too high to significantly affect system performance; direct-drive units will suffer more from this phenomenon unless additional inertia is added (i.e. by a flywheel) or the system uses feedback to actively counter the effect.

Applications

Direct-drive mechanisms are used in applications ranging from low speed operation (such as phonographs, telescope mounts and ski lifts, video game racing wheels and gearless wind turbines)[14][15][16] to high speeds (such as fans, computer hard drives, VCR heads, sewing machines, CNC machines and washing machines.)

Some electric railway locomotives have used direct-drive mechanisms, such as the 1919 Milwaukee Road class EP-2 and the 2007 East Japan Railway Company E331. Several cars from the late 19th century used direct-drive wheel hub motors, as did some concept cars in the early 2000s; however, most modern electric cars use inboard motor(s), where drive is transferred to the wheels, via the axles.[17][18]

Some automobile manufacturers have managed to create their own unique direct-drive transmissions, such as the one Christian von Koenigsegg invented for the Koenigsegg Regera.[19]

See also

References
  1. Asada, H., & Kanade, T. (1983) Design of direct-drive mechanical arms in Journal of Vibration, Acoustics, Stress, and Reliability in Design, Volume 105, Issue 3, pp.312-316
  2. "Auto Repair - Maintenance, Troubleshooting and Car Repair Estimates".
  3. "Why the Porsche Taycan EV's Two-Speed Transmission Is a Big Deal".
  4. "What is a Direct Drive Motor | Electric Torque Machines". Archived from the original on 2018-11-10.
  5. P. Ransome-Wallis (2001) Illustrated Encyclopedia of World Railway Locomotives, p.63
  6. Roy V. Wright (ed.) (1938) Locomotive Cyclopedia of American Practice, section 16 "Diesel locomotives", 10th edition, Association of American Railroads - Mechanical Division, p.973
  7. Baichun Zhang, Marco Ceccarelli (Eds.) Explorations in the History and Heritage of Machines and Mechanisms, p.292
  8. "What is a Strong Magnet?". The Magnetic Matters Blog. Adams Magnetic Products. October 5, 2012. Archived from the original on March 26, 2016. Retrieved October 12, 2012.
  9. Bruno Siciliano, Oussama Khatib (Eds., 2008) Springer Handbook of Robotics, p.80
  10. Robotics Technology Abstracts, Volume 4, Cranfield Press, 1985, p.362, quote: "direct drive. The direct coupling of motors eliminates backlash completely"
  11. United States Armed Services Board of Contract Appeals (1966) Board of Contract Appeals Decisions, Volume 66, Issue 1, p.764, published by Commerce Clearing House
  12. Uday Shanker Dixit, Manjuri Hazarika, J. Paulo Davim (2016) A Brief History of Mechanical Engineering, ch.7 "History of Mechatronics", pp.160-161
  13. K. T. Chau Electric Vehicle Machines and Drives: Design, Analysis and Application, ch.8 "Vernier Permanent Magnet Motor Drives", p.227
  14. "Fanatec Release Details On Their(sic) Direct Drive Wheel - Inside Sim Racing". 4 June 2017.
  15. Patel, Prachi. "GE Grabs Gearless Wind Turbines". Technology Review (MIT). Archived from the original on 31 January 2012. Retrieved 7 April 2011.
  16. Dvorak, Paul. "Direct drive turbine needs no gearbox". Windpower Engineering. Retrieved 7 April 2011.
  17. "In-wheel motor". Nissan Motor Corporation. Archived from the original on 2015-04-04. Retrieved 9 July 2021.
  18. "How Do All-Electric Cars Work?". Alternative Fuels Data Center. U.S. Department of Energy. Archived from the original on 2016-09-30. Retrieved 9 July 2021.
  19. "Koenigsegg creates a new breed of hyper-hybrid with 1,500-hp, transmission-less Regera". New Atlas. 2015-03-17. Archived from the original on 2016-08-12. Retrieved 3 May 2021.
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