Deployable Step Assembly with Swing Arm Actuation
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Solution Overview
Problem
Existing retractable step systems for larger vehicles are complex, space-intensive, heavy, and unsatisfactory, lacking a simple and efficient electrically actuated solution for deployment and retraction.
Innovation Solution
A compact and lightweight electrically actuated deployable step assembly featuring a step base, a step member, and swing arm assemblies connected to an actuator with a plunger that moves the step member between retracted and deployed positions, utilizing a short stroke length and stop members to prevent over-deployment, eliminating the need for gearing systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional retractable step systems are used, then the step function is provided, but the system becomes complex, heavy, and space-intensive
Solution Approach 1:
The step assembly is divided into distinct functional segments: a step base fixed to the vehicle, a step member that moves, and swing arm assemblies that connect them. This segmentation allows each component to be optimized independently, reducing overall complexity while maintaining reliability through modular design
Solution Approach 2:
The swing arm assemblies provide dynamic movement capability, allowing the step member to transition smoothly between retracted and deployed positions. The pivot connections enable controlled motion arcs that simplify the mechanical requirements compared to rigid positioning systems
2Area of stationary object
If traditional retractable step systems are used, then the step function is provided, but excessive space is required for operation
Solution Approach 1:
The step member nests within or alongside the vehicle body when retracted, minimizing the space occupied. The swing arm assemblies are positioned to allow compact storage while providing sufficient clearance for deployment motion, effectively nesting the mechanism within the available vehicle space
3Weight of stationary object
If traditional retractable step systems are used, then the step function is provided, but the system becomes excessively heavy
Solution Approach 1:
Complex and heavy components such as gear systems, motors, and control mechanisms are extracted from the design. The step system relies on simple mechanical advantage through swing arms and plunger actuation, eliminating unnecessary weight while maintaining sufficient structural strength through optimized arm geometry and material selection
4Length of moving object
If a short stroke plunger is used, then space efficiency is improved, but the deployment force requirement increases
Solution Approach 1:
Instead of linear extension, the plunger acts on a swing arm lever that converts the short linear stroke into rotational motion. This dimensional transformation allows a one-inch linear stroke to produce the necessary angular displacement for step deployment, reducing the force requirement compared to direct linear actuation
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 a reliable, space-efficient, and lightweight step system that can be easily integrated into vehicles, offering a simple and dependable operation with reduced complexity and space requirements, enhancing usability and safety.
Implementation Method 1
an actuator is disposed on the step base, wherein the actuator comprises a plunger movable between a retracted position and an extended position. Extension of the plunger causes resultant movement of the first and second swing arm assemblies to move the step member to its deployed position
Implementation Method 2
The actuator further comprises swing arm lever, the swing arm lever moving in a first direction responsive to engagement with a distal end of the plunger when the plunger is moved to its extended position and moving in a second opposing direction responsive to disengagement of the plunger
Implementation Method 3
A shaft is rotatably disposed on the step base, the swing arm lever being disposed on the shaft so that movement of the swing arm lever in said first direction drives the shaft to rotate in a first direction and movement of the swing arm lever in said second direction drives the shaft to rotate in a second direction
Implementation Method 4
Another advantageous feature of the present invention is that the system comprises a stop member which engages a portion of the first or second swing arm assembly when the step member reaches its deployed position to prevent further deployment
Data Source
AI summary
A dependable, simple, safe electrically actuated step system for a larger vehicle, such as a van or truck, which is compact and lightweight, includes a step base, a step member movably secured to the step base between a retracted position and a deployed position, and swing arm assemblies which movably secure the step member to the step base. A plunger actuator moves between a retracted position and an extended position to retract and extend the step, responsive to door position or a manual switch.