3D-Printed Telescoping Actuator With Consolidated Screw Segments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing telescoping actuators have complex designs with multiple components, leading to intricate assembly processes and potential structural weaknesses at connection points, which can be improved through 3D printing to consolidate parts and enhance endurance.
Innovation Solution
A 3D-printed telescoping actuator design featuring a ring gear, carrier, and multiple drive screws and segments, all made as consolidated single pieces, allowing axial movement without spinning, facilitated by interlocking guiderails, knubs, and threaded connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components are used in existing telescoping actuator designs, then the actuator can achieve complex functions and movements, but the assembly process becomes intricate and the structure becomes weaker at connection points
Solution Approach 1:
The patent consolidates multiple separate components (carrier, drive screw, segments, guiderails, knubs) into single 3D-printed pieces. For example, the carrier is printed as one piece that integrates the hollow cylindrical structure, bearing surfaces, and guiderail mounting features. This merging reduces the number of assembly steps while maintaining all necessary functions through integrated design features.
Solution Approach 2:
Each consolidated component performs multiple functions. The carrier serves as both a structural housing and a mounting platform for guiderails and knubs. The drive screw simultaneously provides threaded engagement for axial movement conversion and structural support for segment connections. This multi-functionality is achieved through 3D printing's ability to create complex geometries in single pieces.
2Ease of operation
If multiple components are connected in existing telescoping actuators, then the actuator can achieve telescoping movement, but the connection points become weak points prone to breaking
Solution Approach 1:
The patent eliminates connection points by making each functional assembly a single printed piece. The carrier is printed as one piece with integrated guiderails and knub mounting features, eliminating separate fasteners and joints. The drive screw is printed as one piece with integrated threads and segment connection features, removing the need for separate connection hardware that would create weak points.
Solution Approach 2:
The patent utilizes 3D printing technology to create components with optimized material distribution and internal structures. The printed components can incorporate varying density and reinforcement features within the material itself, creating structurally superior monolithic pieces compared to assembled components with mechanical joints.
3Ease of manufacture
If traditional manufacturing methods are used for telescoping actuator components, then standard parts can be produced, but the design is constrained and assembly is time-consuming
Solution Approach 1:
The patent consolidates multiple manufacturing operations into a single 3D printing process. Features that would traditionally require separate manufacturing steps (machining threads, creating complex geometries, making interlocking features) are all produced in one additive manufacturing operation, enabling rapid prototyping and customization without tooling changes.
Solution Approach 2:
The patent leverages 3D printing's ability to easily modify design parameters and geometries. Components can be customized by changing digital model parameters rather than retooling manufacturing processes. This allows rapid iteration and optimization of component designs while maintaining consistent manufacturing throughput through digital fabrication.
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, enhances structural integrity, and reduces friction, resulting in a more durable and efficient telescoping actuator.
Implementation Method 1
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
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.