Clutch Actuator Output Structure for Easier Gear and Cam Manufacturing
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Solution Overview
Problem
Existing clutch actuators face challenges in moldability and manufacturing complexity due to the integration of cam portions and gear outputs, which limits the ease of setting variations in speed reducers and increases production costs.
Innovation Solution
The clutch actuator design separates the rotation portion and output unit, allowing for the use of different materials and machining methods, improving moldability and reducing costs by forming the rotation portion and output unit from materials with optimal strengths and using a 3k-type strange planetary gear speed reducer to enhance response and load capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the cam portion and gear output are integrated in existing clutch actuators, then the structural compactness is improved, but the moldability and manufacturing complexity deteriorate
Solution Approach 1:
The clutch actuator is divided into separate components: the rotation portion (containing the cam mechanism) and the output unit (containing the gear mechanism). This segmentation allows each part to be manufactured independently using optimal materials and processes, improving moldability while maintaining the compact integrated structure through subsequent assembly.
2Volume of moving object
If the cam portion and gear output are integrated in existing clutch actuators, then the structural compactness is improved, but the adaptability for setting variations in speed reducers deteriorates
Solution Approach 1:
By separating the rotation portion from the output unit, the design enables independent optimization and variation of the speed reducer components. Different speed reducer configurations can be implemented by modifying the output unit without affecting the cam mechanism, thereby improving adaptability while preserving structural compactness.
Solution Approach 2:
The separated output unit design allows a single rotation portion to work with multiple types of speed reducers and output configurations. This universal interface approach enables the same cam mechanism to accommodate various speed reducer variations, enhancing design flexibility and adaptability.
3Ease of manufacture
If the rotation portion and output unit are separated and made from different materials, then the manufacturing ease and cost are improved, but the device complexity increases
Solution Approach 1:
The separation of rotation portion and output unit into different components enables the use of different materials optimized for each function. The rotation portion can use materials suitable for cam mechanisms while the output unit uses materials optimized for gear systems, improving manufacturing ease and reducing costs despite the increased assembly complexity.
Data Source
AI summary
A prime mover is provided in a housing, and can operate by energization and output a torque. A speed reducer can decelerate and output the torque of the prime mover. A rotational translation unit including a rotation portion that rotates relative to the housing when the torque output from the speed reducer is input, and a translation portion that moves relative to the housing in an axial direction when the rotation portion rotates relative to the housing and can change a state of a clutch to an engaged state or a non-engaged state. The speed reducer includes an output unit that outputs the decelerated torque of the prime mover to the rotation portion. The rotation portion is formed of a material different from that of the output unit separately, and is provided to be rotatable integrally with the output unit.