Electric Actuator Spring Assembly Guide Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing electric actuator assembly process is complex and inefficient, leading to potential malfunctions due to gaps between components and misalignment of the spring guides, which can cause play and wire entanglement issues.
Innovation Solution
The actuator design incorporates a gear with a radially inner guide, a radially outer guide, and a receiving hole with a slit to securely engage the spring, along with an installation member featuring a covering wall and a slit to facilitate the assembly of the spring, simplifying the assembly process and eliminating gaps that could cause misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the traditional assembly method with separate spring guides and multiple components is used, then the assembly process becomes complex and time-consuming, but the structural stability and alignment precision are maintained
Solution Approach 1:
The patent combines the radially inner guide and radially outer guide into a single integrated guide structure formed as one piece. This merging of previously separate components simplifies the assembly process by reducing the number of parts that need to be assembled, eliminates misalignment issues between separate guides, and improves productivity while maintaining the functional benefits of having both inner and outer guides for spring support.
Solution Approach 2:
The integrated guide structure serves multiple functions simultaneously: it provides radial guidance for the spring, supports the spring coil, defines the receiving hole geometry, and eliminates the need for separate spring guide components. This multi-functionality reduces assembly complexity and improves manufacturing efficiency while maintaining structural stability.
2Reliability
If separate spring guides are used between the gear and installation member, then the structural design is flexible, but gaps are generated that cause wearing and play
Solution Approach 1:
By merging the radially inner guide and radially outer guide into a single integrated component, the patent eliminates the gap that would exist between separate guide structures. This continuous guide structure provides uninterrupted support for the spring coil, preventing wearing and play while maintaining the necessary structural design flexibility through the integrated geometry.
3Strength
If the fitting portion is securely press fitted into the fitting hole, then the connection strength is improved, but the assembly difficulty and time increase
Solution Approach 1:
The patent incorporates a press-fit portion that is pre-formed on the shaft with the correct dimensions and geometry for interference fitting into the fitting hole. This preliminary preparation of the press-fit portion ensures strong connection when assembled, while the pre-formed nature of the feature reduces assembly time and complexity compared to creating press-fit features during the assembly process.
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 the assembly process, improves productivity, and reduces the likelihood of malfunctions by ensuring proper alignment and secure engagement of the spring, thereby enhancing the reliability and efficiency of the electric actuator.
Implementation Method 1
The spring includes a coil that is spirally wound and is located between the one end portion and the another end portion of the spring. The coil is resiliently deformably received in an inside of the receiving hole.
Data Source
AI summary
In an electric actuator, one end portion of a return spring is hooked to a first slit formed in a radially outer guide of an output gear, so that the return spring is twisted for a predetermined angle that is slightly smaller than an initial set angle. A tilted slit portion is formed at an opening of a second slit that is formed in a covering wall of a spring installation member to twist the return spring to a predetermined initial set angle. Thereby, simultaneously with assembling of a valve shaft to the output gear, the return spring is twisted for the initial set angle. Thus, an assembling work of the electric actuator can be simplified.