Modularly assembled actuator and assembling method thereof

Abstract

The invention relates to the technical field of actuators, and provides a modularly-assembled actuator and an assembling method thereof.The modularly-assembled actuator comprises a power module and a suspension shock-proof module, and the power module comprises an electromagnet, a permanent magnet and a flexible supporting piece which keeps the permanent magnet suspended above the electromagnet and can move left and right; the suspension shock-proof module comprises a suspension adapter, a fixed adapter and an elastic piece for flexibly connecting the suspension adapter and the fixed adapter, and the suspension adapter and the electromagnet are rigidly fixed through the arrangement of structures such as the power module and the suspension shock-proof module, and the power module adopts the design that the width is smaller than the internal width of the suspension shock-proof module; therefore, the device can be directly installed in the vertical direction. The fixed adapter of the suspension shock-proof module is provided with the hole with the optimized size, the top of the power output module is supported to be installed downwards or pre-assembled and integrally installed, the modular design enables all functional units to be assembled and tested independently and then assembled, and the assembling efficiency and the maintenance convenience are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of actuator technology, and more specifically, to a modularly assembled actuator and its assembly method. Background Technology

[0002] In the current trend of the personal care industry towards intelligence, precision and humanization, the performance of actuators, as core execution components, is of paramount importance.

[0003] One structural principle is shown in the figure. The three parts are isolated by two sets of springs. M1 is the power output module, which is fixedly connected to the cutter head in the finished product. M2 is the suspension module, which bears the reaction force of the power output module. M0 is the finished machine housing. Spring K1 flexibly connects M1 and M2. K1, M1, and M2 together form a resonance system. An electromagnetic drive device between M1 and M2 realizes power conversion. Spring K2 connects M2 and M0. Through clever design, the actuator can be installed while minimizing the force ultimately transmitted to the machine housing M0, thereby reducing machine housing vibration and improving user comfort.

[0004] The prior art includes a reciprocating magnetic levitation linear motor and an electric shearing device with application publication number CN116015013 A. A reciprocating magnetic levitation linear motor and an electric shearing device are disclosed. The reciprocating magnetic levitation linear motor includes a support frame, two sets of elastic support modules, a drive assembly, and a motion assembly suspended above the drive assembly. The drive assembly is mounted on the support frame and can drive the motion assembly to reciprocate along a preset direction via electromagnetic action. Both ends of the motion assembly along the preset direction are connected to the support frame via a set of elastic support modules. Each elastic support module includes a leaf spring, a connecting assembly, and a first connecting member. The leaf spring has a first connecting end and a second connecting end. The first connecting end is fixedly connected to the motion assembly, and the first connecting member passes through and fixes the second connecting end to the connecting assembly. The leaf spring is fixedly connected to the support frame via the connecting assembly. The reciprocating magnetic levitation linear motor of this invention exhibits high frequency consistency and small error.

[0005] However, in this design, springs k1 and k2 are both made of stamped metal sheets. The two ends of the spring sheets need to be connected to other components, requiring a lot of auxiliary parts, resulting in a complex structure and high assembly difficulty. Summary of the Invention

[0006] This invention proposes a modularly assembled actuator and its assembly method, which solves the problems of insufficient assembly efficiency and short service life in related technologies.

[0007] The technical solution of the present invention is as follows: a modular assembly actuator, comprising a power module and a suspension and shock absorption module. The power module includes an electromagnet, a permanent magnet, and a flexible support component that keeps the permanent magnet suspended above the electromagnet and can move left and right. The suspension damping module includes a suspension adapter and a fixed adapter, as well as a spring piece that flexibly connects the two. The suspension adapter and the electromagnet are rigidly fixed, and the fixed adapter is installed on the electrical housing. The flexible support component of the power module is made of plastic through injection molding, and the spring sheet on the suspension damping module is made of metal spring sheet. The width of the power module is smaller than the internal width of the suspension damping module. After the two can be assembled in modules, the power module is installed into the suspension damping module from a direction perpendicular to the width.

[0008] As a preferred embodiment of the present invention, it further includes a power output module, the base of which is fixed to the permanent magnet, and the closed opening on the fixing adapter is larger than the base, so as to facilitate the installation of the power output module from top to bottom.

[0009] As a preferred embodiment of the present invention, the opening on the fixed adapter is not completely closed, which facilitates the pre-assembly of the power output module and its overall installation into the suspension damping module.

[0010] As a preferred embodiment of the present invention, the portion where the permanent magnet and the suspension shock absorption module are fixed together is further equipped with a counterweight to further reduce vibration and improve service life.

[0011] As a preferred embodiment of the present invention, the counterweight block is provided with a central notch to allow space for bending of the wire.

[0012] As a preferred embodiment of the present invention, the suspension shock absorption module and the connecting parts at both ends of the spring sheet can be riveted or welded.

[0013] In a preferred embodiment of the present invention, the fixed adapter and the electrical housing are fixedly installed, and the electromagnet is provided with a lead wire, which is connected to the circuit after a large bend.

[0014] An assembly method for a modular assembly actuator, the method comprising the following steps: S1. Module pre-assembly: The power module and suspension damping module are assembled independently. During the assembly of the power module, a flexible support component made of one-piece plastic injection molding is used to keep the permanent magnet suspended above the electromagnet and allow it to move left and right. When assembling the suspension shock absorption module, a spring made of metal spring sheet is used to flexibly connect the suspension adapter and the fixed adapter; S2. Module Integration: The power module assembled in step S1 is inserted into the interior of the assembled suspension and shock absorption module along a direction perpendicular to its width; wherein the width of the power module is smaller than the internal width of the suspension and shock absorption module to achieve smooth assembly; after assembly, the suspension adapter is rigidly fixed to the electromagnet. S3. Complete installation: Install the integrated module onto the electrical housing through the fixing adapter, and connect the lead wire on the electromagnet to the external circuit after making a large bend.

[0015] In a preferred embodiment of the present invention, the power output module is installed in or after step S2; the power output module is installed in one of the following two ways: Method 1: Install the base of the power output module downwards from the closed opening above the fixed adapter, and fix the base to the permanent magnet; wherein the size of the closed opening is larger than the size of the base; Method 2: First, fix the base of the power output module to the permanent magnet in advance, and then install this pre-assembled whole and the power module into the suspension shock absorption module together; wherein, the fixing adapter is provided with an opening that is not completely closed to allow the pre-assembled whole to pass through.

[0016] As a preferred embodiment of the present invention, in step S2, when the levitation adapter is rigidly fixed to the permanent magnet, a counterweight is added to the fixed part; the counterweight is provided with a middle notch to reserve space for bending the lead wire of the electromagnet. Furthermore, during the assembly of the suspension damping module, the spring sheet and the connecting parts at both ends are fixedly connected by riveting or welding.

[0017] The working principle and beneficial effects of this invention are as follows: 1. This invention incorporates a power module and a suspension damping module, among other structures. The power module is designed with a width smaller than the internal width of the suspension damping module, allowing it to be directly installed vertically. The fixing adapter of the suspension damping module has an optimized opening, supporting the top-down installation of the power output module or pre-assembled overall installation. The modular design allows each functional unit to be independently assembled and tested before final assembly, significantly improving assembly efficiency and maintenance convenience.

[0018] 2. This invention utilizes counterweights and spring plates. The addition of counterweights effectively increases the weight of the suspension module m2, reducing the amplitude of m2 while maintaining the same power output amplitude. This reduction in m2 amplitude effectively decreases the force transmitted to the housing and also reduces the total deformation of spring k1, thus mitigating fatigue damage. The metal spring plates are reliably connected via riveting or welding, and their elastic properties provide stable flexible support for the system. The combined effect of these components improves the user experience and ensures the product's durability under long-term vibration conditions. Attached Figure Description

[0019] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0020] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is an exploded view of the overall structure of the present invention; Figure 3 This is a schematic diagram of the overall structure of the electromagnet of the present invention; Figure 4 This is a schematic diagram of the overall structure of the permanent magnet of the present invention; Figure 5 This is a schematic diagram of the overall structure of the flexible support component of the present invention; Figure 6 This is a schematic diagram of the overall structure of the suspension adapter of the present invention; Figure 7 This is a schematic diagram of the overall structure of the power output module of the present invention; Figure 8 This is a schematic diagram of force transmission in this invention.

[0021] In the diagram: 1. Power module; 2. Suspension and shock absorption module; 11. Electromagnet; 12. Permanent magnet; 13. Flexible support component; 21. Suspension adapter; 22. Fixed adapter; 23. Spring; 10. Electrical housing; 3. Power output module; 31. Base; 4. Counterweight; 102. Lead wire. Detailed Implementation

[0022] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1 like Figures 1-7 As shown, in this embodiment, a modular assembly actuator includes a power module 1 and a suspension and shock absorption module 2. The power module 1 includes an electromagnet 11, a permanent magnet 12, and a flexible support 13 that keeps the permanent magnet 12 suspended above the electromagnet 11 and can move left and right. The suspension damping module 2 includes a suspension adapter 21, a fixed adapter 22, and a spring piece 23 that flexibly connects the two. The suspension adapter 21 and the electromagnet 11 are rigidly fixed, and the fixed adapter 22 is installed on the electrical housing 10. The feature is that the flexible support 13 of the power module 1 is made of plastic integral injection molding, the spring 23 on the suspension shock absorber module 2 is made of metal spring, the width of the power module 1 is smaller than the internal width of the suspension shock absorber module 2, and the two can be modularly assembled separately. After the power module 1 is installed into the suspension shock absorber module 2 from the direction perpendicular to the width.

[0024] Specifically, a modular assembly actuator is composed of two independent units: a power module 1 and a suspension and vibration damping module 2. The power module 1, as the source of driving force, consists of an electromagnet 11, a permanent magnet 12, and a crucial flexible support component 13. The electromagnet 11 is fixed to the bottom of the module and generates a controllable magnetic field when energized. The permanent magnet 12 is precisely held directly above the electromagnet 11 by the flexible support component 13, maintaining a suspended state. This flexible support component 13 is made of plastic using a one-piece injection molding process. This design provides sufficient rigidity in the direction perpendicular to the magnetic field to stably support the permanent magnet 12; while in the horizontal direction, parallel to the surface of the electromagnet 11, it exhibits specific flexibility, allowing the permanent magnet 12 to perform controllable left-right reciprocating motion under electromagnetic force. The suspension and vibration damping module 2 is responsible for isolating the vibrations generated by the power module 1 from the final installed electrical housing 10. It includes a suspension adapter 21, a fixed adapter 22, and a spring 23 connecting the two. The spring piece 23 is made of metal and utilizes its elastic deformation capability to provide a flexible suspension support for the entire vibration system. The suspension adapter 21 is rigidly connected to the electromagnet 11 in the power module 1, becoming part of the vibration component; while the fixing adapter 22 is used to install on the electrical housing 10. The key feature of this invention is that the width of the power module 1 is designed to be smaller than the internal width of the suspension damping module 2. This allows the two modules to be assembled and tested independently before the power module 1 is conveniently and accurately installed into the internal space of the suspension damping module 2 along a direction perpendicular to its width, achieving true modular assembly and greatly improving production efficiency and maintenance convenience.

[0025] In this embodiment, a power output module 3 is also included. The base 31 of the power output module 3 is fixed to the permanent magnet 12. The closed opening on the fixing adapter 22 is larger than the base 31, so that the power output module 3 can be installed from the top down.

[0026] Specifically, based on the modular structure of claim 1, this embodiment further integrates a power output module 3. The power output module 3 has a base 31, which is rigidly fixed to the permanent magnet 12 in the power module 1. Therefore, when the permanent magnet 12 moves left and right under the drive of the electromagnet 11, it directly drives the power output module 3 to move synchronously, thereby converting the electromagnetic driving force into an external mechanical action output, such as driving a specific mechanism. To facilitate the installation of the power output module 3, a closed opening is provided on the fixing adapter 22 of the suspension damping module 2. The size of this opening is intentionally designed to be larger than the size of the base 31 of the power output module 3. This design allows the assembly worker to pass the base 31 of the power output module 3 vertically downwards through the opening from the top of the actuator, allowing it to smoothly contact and fix with the permanent magnet 12 below. This "top-down" installation method is highly ergonomic, simplifies the assembly process, avoids complex lateral alignment operations in narrow spaces, and further consolidates the modularity and ease of assembly advantages of the actuator.

[0027] In this embodiment, the opening on the fixed adapter 22 is not completely closed, so that the power output module 3 can be pre-assembled and then installed into the suspension damping module 2.

[0028] Specifically, this embodiment is a further optimization and supplement to the installation method of the power output module 3 in claim 2. In addition to the aforementioned top-down installation method, this embodiment provides another more flexible assembly path. The key lies in the special design of the opening shape on the fixing adapter 22 of the suspension damping module 2. This opening is not a completely closed circle or square, but rather has an opening that allows components to pass through, thus becoming a partially closed opening. Based on this design, the assembly process can be as follows: first, the base 31 of the power output module 3 and the permanent magnet 12 of the power module 1 are pre-assembled and fixed outside the module to form a complete drive unit. Then, this pre-assembled whole is installed into the interior of the suspension damping module 2 through the partially closed opening on the fixing adapter 22. This method provides more options for the process layout of the production line, and is particularly suitable for application scenarios where the circuit board and actuator are connected first before final assembly, demonstrating the powerful flexibility of modular design in adapting to different production processes.

[0029] In this embodiment, the permanent magnet 12 and the suspension shock absorption module 2 are fixed together, and a counterweight 4 is added to further reduce vibration and improve service life.

[0030] Specifically, this embodiment focuses on improving the end-user experience and long-term operational reliability of the actuator. An additional counterweight 4 is added at the point where the electromagnet 11 and the suspension adapter 21 of the suspension damping module 2 are rigidly fixed together. This counterweight 4 is fixed to the suspension components electromagnet 11 and suspension adapter 21, and its core function is to increase the overall mass of the suspension module m2. According to the principles of physics, with the power output amplitude remaining constant, increasing the mass m2 of the corresponding reaction force module can effectively reduce the amplitude of m2, thereby reducing the force transmitted to the housing. For the user, the most direct feeling is a significantly reduced "vibration" sensation. The reduction in the amplitude of m2 also simultaneously reduces the amplitude of key components such as the flexible support 13 and the metal spring 23, thereby reducing fatigue damage and ultimately extending the actuator's service life.

[0031] In this embodiment, the counterweight 4 has a notch in the middle to leave space for bending of the wire.

[0032] Specifically, this embodiment is a detailed optimization of the counterweight 4 structure in claim 4. The added counterweight 4 is not a simple solid metal block, but rather has a notch or through hole intentionally provided in its center. This design is mainly to provide necessary bending space for the electrical leads 102 on the electromagnet 11. The electromagnet 11 needs to be energized to operate, and its leads 102 need to be connected from the fixed part to the circuit board. During actuator operation, there is relative movement between the moving part, carrying the counterweight 4, and the fixed part. If the leads 102 are too taut or the bending radius is too small, long-term repeated bending can easily lead to breakage of the leads 102. The notch in the middle of the counterweight 4 provides a loose, uncompressed wiring route for the leads 102, allowing the leads 102 to make a smooth, large-radius bend. This design fully considers the reliability of the electrical connection and is a model of the collaborative design of mechanical structure and electrical wiring, effectively avoiding equipment failure caused by wire fatigue.

[0033] In this embodiment, the connecting parts at both ends of the suspension shock absorption module 2 and the spring sheet 23 can be riveted or welded.

[0034] Specifically, this embodiment details the connection process of the key elastic element—the metal spring 23—in the suspension damping module 2. The function of the suspension damping module 2 relies on the metal spring 23 achieving a stable and reliable flexible connection between its two ends, namely the suspension adapter 21 and the fixed adapter 22. Therefore, this embodiment clarifies that the fixing of the spring 23 to the two end connectors can employ two mature industrial connection processes: riveting or welding. Riveting uses physical pressing to secure the spring 23 and the connector together through the plastic deformation of the rivet. Its advantages include stable connection, lower cost, and no high temperature involved, thus not affecting the original metal heat treatment properties of the spring 23. Welding, on the other hand, uses high temperature to melt and bond the metal at the connection point. Its advantages include high connection strength, a more compact and integrated structure, and the ability to withstand greater stress. These two process paths provide manufacturers with a choice, allowing them to select the most suitable connection method based on their production line configuration, cost budget, and specific product performance requirements, ensuring production flexibility and product consistency.

[0035] In this embodiment, the fixed adapter 22 and the electrical housing 10 are fixedly installed, and the electromagnet 11 is provided with a lead wire 102, which is connected to the circuit after a large bend.

[0036] Specifically, this embodiment describes the interface and electrical connection details between the actuator and the external environment. The fixing adapter 22 of the suspension and shock absorption module 2 serves as the mounting base for the entire actuator on the electrical housing 10. It is fixedly installed to the electrical housing 10 using screws or clips, thereby securely integrating the actuator body into the final product. Regarding electrical connections, the electromagnet 11 of the power module 1 is provided with necessary electrical leads 102 for connecting to the control circuit to receive drive signals. An important feature is that these leads 102 undergo a "large bend" before being connected to the external circuit board. A "large bend" refers to bending the leads 102 into a large, smooth arc, rather than a sharp right angle. The core principle behind this is that during actuator operation, the electromagnet 11, as part of the bottom of the suspension component, has relative movement with the housing, and its leads 102 are subjected to bending stress. A large bending radius can significantly reduce stress concentration at the bending point of lead 102, prevent the metal core of lead 102 from fatigue fracture due to frequent vibration, greatly improve the long-term reliability and safety of electrical connection, and is one of the key designs to ensure product durability.

[0037] An assembly method for a modular assembly actuator, the method comprising the following steps: S1. Module pre-assembly: The power module 1 and the suspension and shock absorption module 2 are assembled independently. When assembling the power module 1, the permanent magnet 12 is kept suspended above the electromagnet 11 and can move left and right by the flexible support 13 made of one-piece plastic injection molding; When assembling the suspension shock absorption module 2, the suspension adapter 21 and the fixed adapter 22 are flexibly connected by the spring 23 made of metal spring sheet; S2. Module integration: The power module 1, which has been assembled in step S1, is inserted into the interior of the assembled suspension and shock absorption module 2 along a direction perpendicular to its width; wherein, the width of the power module 1 is smaller than the internal width of the suspension and shock absorption module 2 to achieve smooth assembly; after assembly, the suspension adapter 21 is rigidly fixed to the electromagnet 11. S3. Complete installation: Install the integrated module onto the electrical housing 10 through the fixing adapter 22, and connect the lead wire 102 on the electromagnet 11 to the external circuit after making a large bend.

[0038] In or after step S2, the power output module 3 is installed; the power output module 3 is installed in one of the following two ways: Method 1: Install the base 31 of the power output module 3 downward from the closed opening above the fixed adapter 22, and fix the base 31 to the permanent magnet 12; wherein the size of the closed opening is larger than the size of the base 31. Method 2: First, fix the base 31 of the power output module 3 to the permanent magnet 12 in advance, and then install this pre-assembled whole into the suspension damping module 2 together with the power module 1; wherein, the fixing adapter 22 is provided with an opening that is not completely closed to allow the pre-assembled whole to pass through.

[0039] In step S2, when the levitation adapter 21 is rigidly fixed to the permanent magnet 12, a counterweight 4 is added to the fixed part; the counterweight 4 is provided with a middle notch to reserve space for bending the lead wire 102 of the electromagnet 11. Furthermore, during the assembly of the suspension damping module 2, the spring piece 23 is fixedly connected to the connectors at both ends by riveting or welding.

[0040]

[0041] According to theoretical calculations 1. System resonant frequency:

[0042] 2. Handle amplitude:

[0043] M0 - Electrical housing; M1 - Power output module; M2 - Suspension module; K0 - Spring; K1 - Flexible support component.

[0044] 1. f0 is the overall cutting frequency of the machine, which is usually required to be high, so k1 is relatively high; 2. The vibration of the handle is directly proportional to k0, so the smaller k0 is, the better; 3. Increasing the m2 area also helps reduce the sensation of vibration.

[0045] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A modular assembly actuator, comprising a power module (1) and a suspension and shock absorption module (2). The power module (1) includes an electromagnet (11), a permanent magnet (12), and a flexible support (13) that keeps the permanent magnet (12) suspended above the electromagnet (11) and can move left and right. The suspension shock absorption module (2) includes a suspension adapter (21) and a fixed adapter (22) and a spring piece (23) that flexibly connects the two. The suspension adapter (21) and the electromagnet (11) are rigidly fixed, and the fixed adapter (22) is installed on the electrical housing (10). Its features are, The flexible support (13) of the power module (1) is made of plastic injection molding, and the spring (23) on the suspension shock absorber module (2) is made of metal spring. The width of the power module (1) is smaller than the internal width of the suspension shock absorber module (2). After the two can be modularly assembled, the power module (1) is installed into the suspension shock absorber module (2) from the direction perpendicular to the width.

2. The modular assembly actuator according to claim 1 further includes a power output module (3), wherein the base (31) of the power output module (3) and the permanent magnet (12) are fixed, and the closed opening on the fixed adapter (22) is larger than the base (31) to facilitate the installation of the power output module (3) from top to bottom.

3. According to claim 2, the opening on the fixed adapter (22) is not completely closed, so that the power output module (3) can be pre-assembled and then installed into the suspension shock absorber module (2).

4. In the modular assembly actuator according to claim 1, the part where the electromagnet (11) and the suspension damping module (2) are fixed together is further provided with a counterweight (4) to further reduce vibration and improve service life.

5. A modular assembly actuator according to claim 4, wherein the counterweight (4) has a central notch to allow space for wire bending.

6. In a modular assembly actuator according to claim 1, the connecting parts at both ends of the suspension damping module (2) and the spring sheet (23) can be riveted or welded.

7. A modular assembly actuator according to claim 1, wherein the fixed adapter (22) and the electrical housing (10) are fixedly installed, and the electromagnet (11) is provided with a lead wire (102), which is connected to the circuit after a large bend.

8. An assembly method for a modular assembly actuator, characterized in that, The method includes the following steps: S1. Module pre-assembly: The power module (1) and the suspension damping module (2) are assembled independently. When assembling the power module (1), the permanent magnet (12) is kept suspended above the electromagnet (11) and can move left and right by a flexible support (13) made of plastic integral injection molding. When assembling the suspension shock absorption module (2), the suspension adapter (21) and the fixed adapter (22) are flexibly connected by a spring (23) made of metal spring sheet; S2, Module Integration: The power module (1) assembled in step S1 is inserted into the interior of the suspension shock absorber module (2) in a direction perpendicular to its width; wherein the width of the power module (1) is smaller than the internal width of the suspension shock absorber module (2) to achieve smooth assembly; after assembly, the suspension adapter (21) is rigidly fixed to the electromagnet (11); S3. Complete installation: Install the integrated module onto the electrical housing (10) through the fixed adapter (22), and connect the lead wire (102) on the electromagnet (11) to the external circuit after a large bend.

9. The assembly method according to claim 8, characterized in that, In or after step S2, the power output module (3) is installed; the power output module (3) is installed in one of the following two ways: Method 1: Install the base (31) of the power output module (3) downward from the closed opening above the fixed adapter (22), and fix the base (31) to the permanent magnet (12); wherein the size of the closed opening is larger than the size of the base (31); Method 2: First, fix the base (31) of the power output module (3) to the permanent magnet (12) in advance, and then install this pre-assembled whole together with the power module (1) into the suspension shock absorption module (2); wherein, the fixing adapter (22) is provided with an opening that is not completely closed to allow the pre-assembled whole to pass through.

10. The assembly method according to claim 9, characterized in that, In step S2, when the levitation adapter (21) is rigidly fixed to the electromagnet (11), a counterweight (4) is added to the fixed part; the counterweight (4) is provided with a middle notch to reserve space for bending the lead wire (102) of the electromagnet (11); Furthermore, during the assembly of the suspension shock absorption module (2), the spring sheet (23) is fixedly connected to the connectors at both ends by riveting or welding.

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