Linear Actuator Mounting Unit Reduces Assembly Complexity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing linear actuators are complex and expensive to manufacture due to their multi-component designs and rigid material requirements, which complicate assembly and increase production costs.
Innovation Solution
A simplified linear actuator design featuring a mounting unit embedded in the housing with a front and rear end, where the motor is located at the rear end and the spindle is mounted on the front end, reducing component count and assembly complexity, and utilizing a planetary gear transmission and a plastic-moulded activation element with internal threads for easy assembly and waterproofing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a multi-component housing design with separate mounting for motor and spindle is used, then the actuator can accommodate various components, but the assembly complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent combines the motor mounting and spindle mounting functions into a single integrated mounting unit. This mounting unit serves as a common structure that holds both the motor and the spindle, eliminating the need for separate mounting arrangements. The integration reduces the total number of components and simplifies the assembly process while maintaining the ability to accommodate both components effectively.
Solution Approach 2:
The mounting unit is designed as a multi-functional component that performs multiple roles: it mounts the motor, mounts the spindle, and provides structural support. This universal mounting structure replaces what would traditionally require multiple specialized components, thereby reducing complexity while preserving adaptability.
2Strength
If rigid materials like aluminium, zinc alloys or stainless steel are used for housing and outer tube, then the structural strength and rigidity are sufficient, but the manufacturing cost increases
Solution Approach 1:
The patent employs composite materials, specifically plastic materials reinforced with fibreglass, to achieve the required structural strength and rigidity. The fibreglass reinforcement provides the necessary mechanical properties while the plastic matrix allows for cost-effective manufacturing through injection molding. This composite approach replaces expensive metal materials while maintaining structural integrity.
Solution Approach 2:
The patent changes the material parameters by selecting plastic composites with appropriate fiber reinforcement ratios and distributions. By adjusting the fibreglass content and orientation, the material achieves the required rigidity and strength characteristics previously only attainable with metals, but at a lower manufacturing cost.
3Stability of the object's composition
If traditional half-shell housing construction is used, then the housing can enclose components, but the assembly process becomes complex and waterproofing difficult
Solution Approach 1:
The housing is segmented into two simple half-shells that are easy to manufacture and assemble. The mounting unit is integrated into one of these half-shells, creating a modular structure. This segmentation allows for simple snap-fit or screw-together assembly while maintaining effective enclosure. The divided design also simplifies waterproofing by creating clear sealing surfaces at the joint between the two half-shells.
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 design significantly reduces manufacturing costs and simplifies assembly while maintaining actuator performance, making it more economical and efficient to produce without compromising quality.
Implementation Method 1
a transmission in connection with the motor shaft, a spindle unit in connection with the transmission
Implementation Method 2
the spindle unit comprises at least one spindle with a spindle nut
Data Source
AI summary
Linear actuator comprising a housing (1) consisting of two parts (1a, 1b), an electric motor (3) with a motor shaft, a transmission (8-11) in connection with the motor shaft, a spindle unit in connection with the transmission, where the spindle unit comprises at least a spindle (7) with a spindle nut (14) and where the spindle (7) is equipped with a bearing (12), an adjustment element (13) in connection with the spindle unit. The linear actuator is characterized in that a mounting unit (2) is embedded in the housing, said mounting unit (2) has a front and a rear end, and where the motor (3) is placed on the rear end of the mounting unit (2) and the spindle (7) is mounted on the front end of the mounting unit (2), and where the transmission (8-11) is located inside the mounting unit (2). In addition to being able to reduce the number of components with this construction, e.g. the activation element (13), the front mounting (15) and the spindle nut (14) can be moulded as one single plastic unit, it also allows for a slackening of the tolerances as the assembly of the components is considerably simplified, namely only with regard to the mounting unit (2). In that connection, the transmission (8-11) is expediently placed in the mounting unit (2).