Actuator Unit Design for Drug Device Assembly
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Solution Overview
Problem
Existing actuator units for medical devices require complex insert molding processes, leading to a cumbersome assembly with a high number of parts and potential instability, especially when integrating electric motors, gear wheels, and conductor stampings.
Innovation Solution
A compact actuator unit design featuring a double-sided support plate with pockets and projections for secure mounting of components, including an electric motor, gear wheels, and conductor stampings, utilizing clamping pockets and a retaining washer for a self-reinforcing clamping effect, and ultrasonic welding for assembly, which reduces the number of parts and simplifies the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a complex insert molding process is used to assemble actuator components, then the components can be integrated, but the manufacturing complexity and number of parts increase
Solution Approach 1:
The patent combines multiple actuator components (motor, gear wheels, conductor stampings, support plate) into a single integrated assembly using insert molding. The motor is molded directly onto the support plate, conductor stampings are embedded in the gear wheel assembly, and all components are secured together in one manufacturing process, reducing the number of separate parts while maintaining manufacturing ease
Solution Approach 2:
The support plate serves multiple functions simultaneously: it provides structural support, acts as a mounting base for the motor, serves as a conductor carrier, and functions as a gear wheel holder. This multi-functionality reduces the need for separate components and simplifies the overall assembly
2Adaptability or versatility
If multiple separate components are used in the actuator assembly, then flexibility in assembly is improved, but the stability and reliability of component fixation deteriorates
Solution Approach 1:
The motor is pre-molded onto the support plate in a predetermined position and orientation, ensuring precise alignment and stable fixation. The conductor stampings are pre-embedded in the gear wheel assembly before final assembly, guaranteeing proper electrical connections and mechanical stability without requiring complex post-assembly adjustments
3Ease of operation
If traditional assembly methods are used for mounting motor and gear components, then ease of assembly is maintained, but the compactness and space utilization of the actuator deteriorates
Solution Approach 1:
The gear wheels are nested within the motor housing structure, with the pinion gear positioned inside the motor assembly and the gear wheel mounted on the motor shaft within the available space. This nested arrangement maximizes space utilization and achieves compact actuator dimensions while maintaining ease of assembly through the integrated molding 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
The solution provides a secure, compact, and space-saving actuator unit with reduced parts, ensuring reliable fixation and easy mounting of components, enhancing the stability and efficiency of medical device assemblies.
Implementation Method 1
The preferred joining process for this is ultrasonic welding, because this is a well-known method.
Data Source
AI summary
An actuator unit includes a support plate having a first side and a second side; an electric motor with terminal lugs and a motor shaft; a motor mounting pocket on the first side, the motor mounting pocket accommodating the electric motor; mounting projections on the first side, the mounting projections including a plurality of clamping pockets; a PC-board insertion slot on the first side; a motor shaft passage from the first side to the second side; the motor shaft of the electric motor projecting from the first side through the shaft passage to the second side and carrying a pinion; a multistage reduction gear arranged on the second side and meshing with the pinion; and a plurality of conductor stampings fixed in the clamping pockets and connected with the terminal lugs of the electric motor.