Electro-Mechanical Actuator Push Rod Vacuum Prevention
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Solution Overview
Problem
Electro-mechanical actuators face restricted movement due to vacuum formation and the push rod manufacturing process is expensive, time-consuming, and generates excessive waste material.
Innovation Solution
A push rod with a flange that extends radially from the body to encircle it, featuring a channel opening to facilitate fluid flow and prevent vacuum formation, combined with a manufacturing method involving drawing, swaging, and forging to reduce waste and improve throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the push rod engages the core pole surface tightly, then the actuator generates sufficient force, but a vacuum forms that restricts push rod movement
Solution Approach 1:
The push rod incorporates a porous structure with channels that allow fluid permeation between the engagement surface and the core pole surface. This porous design enables the push rod to maintain tight engagement for force generation while allowing fluid flow to prevent vacuum formation, thus resolving the contradiction between generating sufficient force and maintaining ease of movement.
2Strength
If the push rod is manufactured by machining solid billet, then the structural integrity is ensured, but the manufacturing process is expensive, time-consuming, and generates excessive waste
Solution Approach 1:
The manufacturing process transitions from machining solid billet to forming processes (such as forging or casting) that change the fundamental approach to material utilization. These processes maintain the structural integrity of the push rod while significantly improving manufacturing throughput and reducing waste material, as the push rod is formed directly from the material rather than being cut from a larger billet.
3Manufacturing precision
If the push rod is manufactured by machining solid billet, then the manufacturing precision can be achieved, but the production time and cost increase significantly
Solution Approach 1:
The push rod is pre-formed using forging or casting processes that create the basic shape and structure before final machining operations. This preliminary action establishes the fundamental geometry and material properties, reducing the amount of material removal needed in subsequent precision machining steps, thereby maintaining manufacturing precision while significantly reducing overall production time.
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
Prevents lock-up and ensures smooth operation of the push rod by equalizing fluid pressure, while reducing production costs and waste through efficient manufacturing processes.
Implementation Method 1
The perimeter surface defines a perimeter opening at the channel for facilitating flow of a fluid into the channel between the engagement surface and the pole surface of the core for preventing a vacuum therebetween when the engagement surface abuts the pole surface of the core
Data Source
AI summary
A push rod for use in a vehicle with an electro-mechanical actuator system, which has an armature and a core, selectively moves an object of the vehicle as the armature moves between first and second positions. The push rod includes a body and a flange extending radially away from the body to a perimeter surface. The flange has an engagement surface defining a channel. The perimeter surface defines a perimeter opening at the channel for facilitating flow of a fluid into the channel between the engagement surface and the core for preventing a vacuum therebetween. A method of manufacturing the push rod includes the steps of providing a material, and drawing and swaging the material to produce the push rod.