Actuator Compound Gear Integrally Molded Resin Metal
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Solution Overview
Problem
Actuators with compound gears, comprising metal and resin gears, face issues such as rattling and damage due to dimensional inaccuracies, assembly errors, temperature changes, torque application, and vibrations, leading to potential gaps and reduced durability.
Innovation Solution
An actuator design featuring a speed reducer with a compound gear where the resin gear is integrally molded with the metal gear, eliminating gaps between them, enhancing durability against temperature changes, gear torque, and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate metal gear and resin gear are assembled to form compound gear, then manufacturing flexibility and material selection are improved, but assembly gaps and dimensional inaccuracies occur leading to rattling and reduced reliability
Solution Approach 1:
The patent merges the metal gear and resin gear into a single integrally molded compound gear unit. The resin gear is molded directly onto the metal gear in one manufacturing process, eliminating the separate assembly step. This integration removes the interface between two separate components, thereby eliminating assembly gaps and dimensional inaccuracies that cause rattling, while preserving the ability to select different materials for different gear portions.
Solution Approach 2:
The patent performs the joining of metal gear and resin gear during the preliminary molding process itself, rather than as a subsequent assembly step. The resin gear is molded directly onto the metal gear while the metal gear is still in position, ensuring precise dimensional alignment before any assembly operations. This preliminary integration prevents later dimensional inaccuracies and assembly gaps.
2Ease of manufacture
If separate metal gear and resin gear are assembled, then ease of manufacture and production flexibility are improved, but temperature changes and vibrations cause gap formation and damage
Solution Approach 1:
The patent combines the manufacturing of metal gear and resin gear into a single integrally molded process. The resin gear is molded directly onto the metal gear, creating a permanent bond that cannot separate under temperature changes or vibrations. This merged structure eliminates the weak interface that would otherwise form gaps and fail under environmental stress.
Solution Approach 2:
The patent creates a composite gear structure where resin material is permanently bonded to metal material in an integral configuration. This composite construction leverages the advantages of both materials (metal strength and resin damping properties) while creating a unified structure that resists separation under temperature variations and vibrational loads, significantly improving connection durability.
3Ease of operation
If separate metal gear and resin gear are used, then component independence and ease of replacement are improved, but wear and gap formation reduce actuator durability
Solution Approach 1:
The patent merges the metal gear and resin gear into a single compound gear unit that functions as one integrated component. This integration eliminates the wear interface between separate gears, preventing gap formation and extending the actuator's service life. The compound gear is designed to be replaced as a single unit, maintaining ease of replacement while eliminating progressive wear damage.
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
The integrated resin and metal gear configuration improves the actuator's durability by preventing gap formation and wear, ensuring reliable operation under varying conditions.
Implementation Method 1
the resin gear is integrally molded with the metal gear, eliminating gaps between them
Data Source
AI summary
An actuator includes an electric motor, an output shaft and a speed reducer. The speed reducer is configured to transmit rotation, which is outputted from the motor, to the output shaft after reducing a speed of the rotation outputted from the motor. The speed reducer includes an output gear joined to the output shaft and a compound gear. The compound gear includes a large diameter gear, which has a plurality of large gear teeth, and a small diameter gear, which has a plurality of small gear teeth. One of the large diameter gear and the small diameter gear is a metal gear, which is made of a metal member, while another one of the large diameter gear and the small diameter gear is a resin gear, which is made of a resin member, and the resin gear is integrally molded together with the metal gear in one piece.