Compact Rack Linear Drive With Integrated Electronics and Torque
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Solution Overview
Problem
Existing electric linear drives for toothed racks are not compact, easy to assemble, or adaptable for different applications, often requiring individualization and complex assembly processes, and lack integration of drive electronics for simplified connection to devices.
Innovation Solution
A compact electric linear drive design featuring a pot-shaped housing with a holding plate that serves as both a fastening structure and cover, incorporating a stepping motor with a rotor axis perpendicular to the toothed rack, and integrated drive electronics for easy connection via a bus system, allowing for flexible adaptation to various applications and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a flat stepper motor with rotor axis in the direction of smallest extension is used, then the drive is compact and suitable for flat linear drives, but the torque required for many applications cannot be generated
Solution Approach 1:
The patent changes the orientation of the rotor axis from the direction of smallest extension to a direction perpendicular to the toothed rack. This dimensional reorientation allows the motor to generate sufficient torque while maintaining a compact overall design, as the motor's rotational force is now effectively transmitted to the rack through the gear mechanism.
Solution Approach 2:
The patent integrates the gear mechanism within the motor housing, nesting the gear inside the motor assembly. This allows the motor and gear to occupy the same spatial envelope, maintaining compactness while enabling the motor to generate adequate torque through the gear's mechanical advantage.
2Adaptability or versatility
If individualized design for specific drive task is implemented, then the drive is optimized for that task, but different devices cannot be driven and assembly becomes complex
Solution Approach 1:
The patent designs the linear drive with universal mounting features and standardized interfaces that allow it to drive different types of devices. The motor assembly can be mounted in various orientations and connected to different rack configurations, enabling one drive design to serve multiple applications without requiring individual customization.
Solution Approach 2:
The patent separates the motor assembly from the mounting bracket, allowing the motor unit to be pre-assembled and tested independently, then easily mounted to different devices. This segmentation simplifies assembly and replacement while maintaining application-specific optimization through the mounting configuration.
3Ease of manufacture
If multiple separate components are used for housing and fastening, then each component can be optimized for its function, but the number of components increases and assembly becomes difficult
Solution Approach 1:
The patent integrates the mounting bracket functions directly into the motor housing, combining the structural support, mounting, and fastening functions into a single integrated component. This eliminates the need for separate brackets and fasteners, reducing the total number of parts while maintaining the ability to optimize each function within the integrated design.
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 enables a robust, easy-to-assemble linear drive with high positioning accuracy and sufficient torque for most applications, facilitating quick and precise assembly with devices like hydraulic valves, while minimizing component count and electrical supply costs.
Implementation Method 1
stepping motor (4) with a stator (6), a rotor shaft (5) and a motor output gear (7)
Data Source
Figure 1
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AI summary
The present invention relates to an electric linear drive (1) for a rack (3) comprising a stepper motor (4), a mounting plate (8), a motor output gear (7), and a gearbox (9), wherein the mounting plate (8), stepper motor (4) with motor output gear (7), and gearbox (9) form a drive unit (14) which, together with a base housing (15), forms an overall housing (16), and wherein the overall housing (16) has an opening (17) for inserting the rack (3). Preferably, drive electronics (19) are additionally attached to the mounting plate (8), in particular integrated into it, such that electrical connections (20) are provided on the outside of the overall housing (16). Furthermore, the stepper motor (4) preferably has a rotor shaft (5) which is arranged parallel to the mounting plate (8). Only a few steps are required for assembly.A rack (3) belonging to a device (2) to be driven can be inserted into a lateral opening (17) of the overall housing (16), and the device (2) to be driven can be connected to the overall housing (16). The invention offers particular advantages when devices (2) to be driven are located close to one another, especially hydraulic valves. The linear actuator (1) according to the invention can be manufactured in a very compact form, for example, with a height (H) of less than 50 mm, a width (B) of less than 150 mm, and a length (L) of less than 150 mm.