Deployable Rock Rail Assembly With Worm-Drive Pivot Stops
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Solution Overview
Problem
Existing vehicles lack a practical mechanism for deploying and stowing protective rock rails that also serve as running boards, while ensuring secure positioning and protection against over-travel and impact damage.
Innovation Solution
A rock rail assembly with a motor-driven pivot system, featuring a sector gear engaged with a worm gear, allows the rail to transition between stowed and deployed positions, using abutments to prevent over-travel and incorporating shock absorption pads for impact protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a motor-driven pivot system with sector gear and worm gear is used to deploy and stow the rock rail, then the rail can transition between stowed and deployed positions, but the device complexity increases
Solution Approach 1:
The rock rail assembly serves multiple functions: it provides obstacle protection when deployed and acts as a running board for passenger entry/exit. The motor-driven pivot system with sector gear and worm gear enables a single component to perform both protective and accessibility functions by transitioning between stowed and deployed positions.
Solution Approach 2:
The sector gear engaged with the worm gear portion of the motor shaft acts as an intermediary mechanism to convert rotational motor motion into controlled pivotal movement of the rail assembly. This intermediary gear system provides precise control over the deployment and stowing actions.
2Manufacturing precision
If abutments are added to prevent over-travel of the rail, then positioning accuracy improves, but the device complexity increases
Solution Approach 1:
The abutments are pre-positioned on the mounting structure to define the exact limits of rail travel before operation begins. The first abutment prevents over-travel in the deployed position while the second abutment prevents over-travel in the stowed position, ensuring accurate positioning without requiring complex control systems.
Solution Approach 2:
The abutments provide self-limiting mechanical stops that automatically prevent over-travel of the rail assembly. When the rail reaches its deployed or stowed position, the sector gear abuts against the corresponding abutment, creating a mechanical stop that requires no external control or monitoring systems.
3Reliability
If shock absorption pads are added to protect against impact damage, then the reliability improves, but the device complexity increases
Solution Approach 1:
Shock absorption pads are pre-installed on the mounting structure at positions where impact is most likely to occur. These pads are positioned to absorb shocks and impacts before they can damage critical components like the motor, gear system, or mounting structure, providing proactive protection rather than reactive damage control.
4Adaptability or versatility
If the rail is made deployable and stowable to serve as both protection and running board, then the versatility improves, but the stability of the structure may worsen
Solution Approach 1:
The rock rail assembly transitions from a static fixed structure to a dynamic movable structure that can pivot between stowed and deployed positions. The motor-driven pivot system with sector gear and worm gear provides controlled movement while maintaining structural integrity during transition and in both position states.
Solution Approach 2:
The patent employs a simple yet effective mechanical pivot system using readily available components like sector gear, worm gear, and basic mounting brackets. This approach uses simpler, more robust components rather than complex expensive mechanisms, prioritizing reliability and ease of manufacture over minimal complexity.
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 assembly provides effective protection from obstacles and serves as a convenient step, while preventing rail over-extension and mitigating damage through mechanical stops and shock absorption.
Implementation Method 1
a worm gear portion disposed between the first and second ends. Operation of the motor drives rotation of the shaft. The sector gear is operably engaged with the worm gear portion of the shaft, such that rotation of the shaft by the motor drives pivotal movement of the pivot bar
Data Source
AI summary
A rock rail assembly for a vehicle includes a mounting structure, an arm mounted to the mounting structure, a motor bracket coupled to the mounting structure, a motor mounted to the motor bracket, a pivot bar pivotably coupled with the mounting structure, a rail coupled with the pivot bar and operable to move between stowed and deployed positions, and a sector gear coupled to the pivot bar. The motor has a shaft that includes a first end, a second end, and a worm gear portion. Operation of the motor drives rotation of the shaft. The sector gear is operably engaged with the worm gear portion of the shaft, such that rotation of the shaft by the motor drives pivotal movement of the pivot bar relative to the mounting structure, causing movement of the rail coupled thereto between the stowed and deployed positions.