3D-Printed Telescoping Actuator Assembly With Consolidated Parts
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Solution Overview
Problem
Existing telescoping actuators have complex designs with multiple components, leading to assembly challenges and reduced endurance due to numerous connecting points, and lack customization options for optimized performance.
Innovation Solution
A 3D-printed telescoping actuator design that consolidates multiple components into single pieces, utilizing a ring gear, carrier, and drive screws connected via interlocking gears and guiderails, allowing axial movement but preventing spinning, facilitated by 3D printing for customized shapes and detailed features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are used in existing telescoping actuator designs, then the actuator can achieve functional requirements, but the design complexity increases and assembly becomes more difficult
Solution Approach 1:
The patent consolidates multiple separate components into single integrated 3D-printed parts. Specifically, the carrier assembly merges the carrier, guiderails, and knurls into one piece; the drive screw assembly merges the drive screw, gear, and connector into another piece. This reduction in component count directly addresses the technical contradiction by simplifying the design while maintaining functional requirements and improving endurance through fewer connecting points.
2Reliability
If multiple connecting points are used to assemble components, then the actuator can be constructed, but the endurance is reduced due to potential failure at connecting points
Solution Approach 1:
The patent eliminates multiple connecting points by consolidating components into integrated 3D-printed assemblies. The carrier assembly and drive screw assembly are each manufactured as single pieces, removing the need for bolts, welds, or other connections between these components. This significantly improves endurance by eliminating potential failure points while the modular assembly of the two main pieces maintains ease of manufacture.
3Ease of manufacture
If standard manufacturing methods are used, then production is straightforward, but customization of component shapes for optimized performance is limited
Solution Approach 1:
The patent utilizes 3D printing technology to enable customization of component geometries and features. The carrier assembly, drive screw assembly, and other components can have their shapes, sizes, and internal structures optimized for specific performance requirements through digital model modifications. This maintains ease of manufacture through additive manufacturing while providing extensive adaptability and customization options that traditional manufacturing methods cannot achieve.
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
Simplifies manufacturing and assembly processes while enhancing the endurance of telescoping actuators by reducing the risk of structural failure at connecting points and enabling optimized performance through customized designs.
Implementation Method 1
a first drive screw placed inside the carrier... the first segment is connected to the first drive screw via a first pair of slopes or a first pair of one or more threads, such that the first segment is able to move in an axial direction with regard to the carrier in response to that the first drive screw spins with regard to the carrier
Implementation Method 2
the first segment is connected to the carrier via one or more first guiderails on the carrier interlocking with one or more first pairs of knubs on the first segment, such that the first segment is able to move in the axial direction with regard to the carrier but unable to spin with regard to the carrier
Implementation Method 3
the first drive screw is connected to the ring gear via one or more gears, such that the first drive screw is able to spin with regard to the carrier in response to that the ring gear spins with regard to the carrier
Data Source
AI summary
The presently disclosed technology teaches a 3D-printed telescoping actuator. The 3D-printed telescoping actuator includes a ring gear, a carrier, one or more segments and drive screws. The segments and drive screws are made as consolidated single pieces. When the ring gear spins, the drive screws spins with the ring gear, and drive the segments to move in an axial direction and reach an extended state. The introduction of 3D printing could enable a plurality of parts in existing designs to be consolidated as a single piece, so fewer parts are needed in the presently disclosed actuator, which simplifies the design and manufacturing processes. Including fewer parts could also improve the durability of the actuator. Nevertheless, using consolidated parts also introduces brand-new assembly challenges. Therefore, additional features are introduced in the presently disclosed technology to facilitate the assembly process.