High-Load Linear Actuator Worm Wheel Assembly Design
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Solution Overview
Problem
Conventional linear actuators are inadequate for high-load applications, such as medical apparatus and electric chairs, as they fail to ensure safety and comfort due to insufficient load-bearing capacity and speed control of the telescopic pipe.
Innovation Solution
A high-load linear actuator design incorporating a driving mechanism with a worm shaft, worm wheel assembly, lead screw, and telescopic pipe, featuring a retardation transmission mechanism with rolling needles and a torque spring to control friction and speed, ensuring stable support and secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional linear actuator components are used, then the structure is simple, but the load-bearing capacity is insufficient for high-load applications
Solution Approach 1:
The patent combines multiple support functions into the worm wheel assembly by integrating two bearings that jointly support the worm wheel inside the ring body, creating a merged support structure that enhances load-bearing capacity while managing structural complexity
Solution Approach 2:
The base is divided into functional portions: a supporting portion with seat and hollow cylinder, and an accommodating portion with ring body. This segmentation allows each portion to be optimized for its specific function while contributing to overall structural integrity for high-load applications
2Speed
If the telescopic pipe moves at high speed, then productivity is improved, but safety and comfort of users are compromised
Solution Approach 1:
The retardation transmission mechanism provides speed control feedback through the interaction of rolling needles with the intermediate ring and torque spring, automatically adjusting the telescopic pipe speed to maintain safety and comfort while preserving productivity
Solution Approach 2:
The friction-based retardation mechanism dynamically adjusts resistance based on load conditions, allowing the telescopic pipe to move at optimized speeds that balance productivity with user safety and comfort across varying operational conditions
3Ease of repair
If the lead screw is easily removable, then ease of repair is improved, but stability of support is reduced
Solution Approach 1:
The worm wheel assembly is segmented as a separate removable unit from the base, allowing the entire assembly containing the worm wheel and bearings to be easily removed for repair while the segmented design maintains stable support when assembled
Solution Approach 2:
The ring body acts as an intermediary structure that provides stable support for the worm wheel while allowing the entire assembly to be easily installed or removed as a unit, balancing stability with ease of repair
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 enhanced stability and reduced assembly time, maintaining constant speed and comfort across varying loads, preventing the lead screw from sliding and optimizing user experience in high-load environments.
Implementation Method 1
the friction of each rolling needle with the intermediate ring, the lead screw can be rotated in a specific direction and hindered to achieve the retardation effect
Implementation Method 2
The intermediate ring is used for rotating the torque spring easily, such that the transmission mechanism has a good transmission performance
Implementation Method 3
The friction produced between the transmission components increases with the load, so that if there is no load, there will be no unnecessary friction or any power consumption
Data Source
AI summary
A high-load linear actuator includes a driving mechanism, a worm shaft, a worm wheel assembly, a lead screw, a telescopic pipe and an outer pipe. The driving mechanism includes a base and a motor. The base has a supporting portion and an accommodating portion. The motor is fixed to the supporting portion. The worm shaft extends from the motor into the supporting portion. The worm wheel assembly includes a worm wheel and two bearings for supporting the worm wheel in the accommodating portion. The worm wheel is engaged with the worm shaft. The lead screw is disposed through the worm wheel and driven by the motor for rotation. The telescopic pipe slips on the lead screw to be threadedly connected therewith. The outer pipe slips on the telescopic pipe. The rotation of the lead screw drives the telescopic pipe to linearly extend or retract relative to the outer pipe.