Asymmetric Pinion-Rack Piston for High-Pressure Air Generation
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Solution Overview
Problem
Existing devices for cleaning in-vehicle cameras struggle with efficient high-pressure air generation, leading to suboptimal removal of foreign matters like water droplets and mud from camera lenses.
Innovation Solution
A cleaner system featuring a high-pressure air generation unit with a piston-cylinder configuration, a worm gear mechanism, and a pinion-rack system that increases piston movement and displacement, allowing for efficient high-pressure air generation while minimizing unnecessary meshing and potential clogging issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional piston-cylinder configuration is used for high-pressure air generation, then the structure is simple, but the piston movement amount is insufficient leading to low efficiency
Solution Approach 1:
The pinion is designed with asymmetric tooth spacing where the interval between adjacent gear teeth varies at different positions. Specifically, the interval between gear teeth on one side of the pinion is different from the interval on the other side, creating an asymmetric tooth pattern that converts rotational motion into extended linear piston displacement, thereby increasing the piston movement amount and high-pressure air generation efficiency
Solution Approach 2:
The movement mechanism dynamically adjusts the piston position through the interaction between the rotating pinion with variable tooth intervals and the rack. As the pinion rotates, the varying tooth intervals cause the rack to move through a larger displacement range, dynamically optimizing the piston stroke length to maximize air compression efficiency
2Reliability
If the nozzle is clogged with foreign matter, then cleaning effectiveness decreases, but the high-pressure air generation unit may suffer damage or produce abnormal sounds
Solution Approach 1:
The system incorporates a relief mechanism that activates when the nozzle becomes clogged. The asymmetric pinion-rack mechanism allows the piston to continue its motion cycle without generating excessive pressure buildup, effectively cushioning against the harmful effects of nozzle clogging before damage can occur to the high-pressure air generation unit
Solution Approach 2:
The design converts the potentially harmful condition of nozzle clogging into a benign state by allowing the piston to complete its full stroke range. The extended piston movement capability ensures that even when the nozzle is blocked, the system can safely discharge pressure through alternative paths or maintain operational safety without compromising the reliability of the high-pressure air generation unit
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 system efficiently generates high-pressure air with a simple configuration, effectively removing foreign matter from camera lenses without causing damage or abnormal sounds, even when the nozzle is clogged, and simplifies the structure of the pinion and rack components.
Implementation Method 1
an urging spring configured to urge the piston
Implementation Method 2
a movement mechanism configured to move the piston to a predetermined position by applying a moving force to the piston, wherein the movement mechanism comprises a worm configured to rotate by a driving unit, and a worm wheel meshed with the worm
Implementation Method 3
the piston is coupled with a rack having a plurality of rack teeth configured to mesh with the plurality of gear teeth
Data Source
AI summary
A cleaner includes a high-pressure air generation unit and a nozzle. The high-pressure air generation unit includes a cylinder, a piston supported to the cylinder to be freely moveable and deliver the high-pressure air toward the nozzle, an urging spring urges the piston, and a movement mechanism which moves the piston to a predetermined position. The movement mechanism comprises a worm which rotate by a driving unit, and a worm wheel meshed with the worm and which rotate in association with rotation of the worm. The worm wheel comprises a pinion having gear teeth protruding from an outer periphery thereof. The piston is coupled with a rack having rack teeth which mesh with the gear teeth, and wherein an interval between each gear tooth of the gear teeth and one adjacent gear tooth is different from an interval between each gear tooth and the other adjacent gear tooth.