Linear Actuator Housing with Molded Bending Tabs
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing linear actuators have high investment costs and maintenance-intensive production lines due to complex connection technologies like laser or ultrasonic welding, which are prone to failure under certain climatic conditions.
Innovation Solution
A linear actuator design featuring a sleeve-like housing with molded flexible shackles that engage in groove-like recesses in the bearing seat and flange, providing a double bending lug closure for component fixation without additional connection techniques, utilizing a combined positive and non-positive connection between the housing and components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If laser or spot welding is used to fix the stator core and flange, then the connection strength is improved, but the manufacturing cost and maintenance requirements increase
Solution Approach 1:
The patent replaces welding technology (laser or spot welding) with a mechanical interlocking system consisting of molded-in flexible shackles and groove-like recesses. This substitution eliminates the need for complex welding equipment while achieving secure mechanical connection between the housing, bearing seat, and flange components.
Solution Approach 2:
The patent uses simple molded flexible shackles integrated into the housing instead of expensive welding processes. These plastic-based mechanical fastening elements are cost-effective to manufacture and eliminate the need for maintenance-intensive welding equipment.
2Productivity
If laser or ultrasonic welding equipment is used, then the production efficiency is improved, but the maintenance intensity and failure risk increase
Solution Approach 1:
The patent replaces complex welding equipment (laser or ultrasonic welding machines) with a simple mechanical interlocking system using molded flexible shackles. This substitution maintains production efficiency through automated molding while eliminating the maintenance and reliability issues associated with welding equipment.
Solution Approach 2:
The flexible shackles are molded directly into the housing, creating a self-contained fastening system that requires no external welding equipment or complex assembly aids. The system is self-sufficient and eliminates dependency on maintenance-intensive production equipment.
3Reliability
If additional locking means and assembly aids are used, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The patent combines the housing, fastening elements (flexible shackles), and component retention features (groove-like recesses) into a single integrated structure. The flexible shackles are molded directly into the housing, eliminating the need for separate locking means and assembly aids while maintaining connection reliability.
Solution Approach 2:
The housing serves multiple functions: it provides structural enclosure, contains the flexible fastening shackles, provides groove-like recesses for component retention, and eliminates the need for separate locking mechanisms. This multi-functionality reduces overall device complexity while maintaining reliability.
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
This design simplifies and cost-effectively manufactures linear actuators, reducing maintenance needs and increasing operational reliability by eliminating the need for additional locking means and assembly aids, resulting in more robust and efficient production lines.
Implementation Method 1
The formed flexible tabs extend as strip-like segments in the direction of the longitudinal axis of the housing, the segments being formed by a profile-like end face in the form of teeth or a silhouette
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a linear actuator (1), comprising at least a stator (3) placed within a sleeve-like housing (2), a bearing ring (4) arranged downstream of the stator (3) in the assembly state with a bearing seat for receiving a rotor (5) with a rolling bearing (6), a spindle (7) which on its drive side (7.1) is designed together with the rotor (5) as a motion converter for converting the rotary motion into a translational motion, and a flange (9) closing the housing (2) on the output side (8) of the linear actuator (1) with anti-rotation device for the output side (7.2) of the spindle (7) penetrating the flange (9). According to the invention, the sleeve-like housing (2) has several formed bending tabs (10.1, 10.2), of which, in the assembly state, first bending tabs (10.1) are inserted into groove-like recesses (11) of the bearing ring (4) of the rolling bearing (6) and second bending tabs (10.2) engage in groove-like recesses (11) of the flange (9), thereby clamping all components (3, 4, 5, 7 and 9) placed in the housing against each other without the need for further joining techniques.