Electric Door Lock Actuator with Bidirectional Force Control
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Solution Overview
Problem
Electrically operated motor vehicle door locks often require excessive electric motor power and gear ratios to provide sufficient force for opening, especially under extreme conditions or after deformation, which is inefficient and impractical.
Innovation Solution
A door lock with a rotatable actuator driven by an electric motor and gearbox, featuring a cable winch or rod mechanism that allows opening with varying forces depending on the direction of rotation, enabling quick low-force operation and higher force when needed, with sensors monitoring the actuator position to control the opening process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional release mechanism is used, then the structure is simple, but the force is insufficient to open the locking mechanism under extreme conditions or after deformation
Solution Approach 1:
The actuating device is designed to provide different forces depending on the direction of rotation of the actuator. In one direction, it provides high force for opening after deformation or under extreme conditions. In the opposite direction, it provides low force for quick opening during normal operation. This dynamic force adjustment resolves the contradiction by providing high force when needed without permanently increasing device complexity.
Solution Approach 2:
The system changes the force parameter by altering the direction of rotation of the actuator. The control unit selects different rotation directions based on the operational state, thereby changing the force output from high to low. This parameter change allows the same mechanical structure to provide varying forces without requiring multiple separate mechanisms.
2Reliability
If a large electric motor and high gear ratio are used, then sufficient force is provided for opening under extreme conditions, but energy expenditure increases and the device becomes overly complex
Solution Approach 1:
The system dynamically adjusts the force application based on operational requirements. During normal operation, low force is applied for quick opening, reducing energy consumption. Only when extreme conditions are detected does the system switch to high force mode, ensuring reliability is maintained only when necessary, thereby avoiding unnecessary energy expenditure.
Solution Approach 2:
The system uses sensors to monitor the state of the locking mechanism and automatically selects the appropriate opening mode. The control unit determines whether high or low force is needed based on real-time conditions, making the system self-regulating and avoiding excessive energy consumption by activating high-force mode only when truly necessary.
3Reliability
If a large electric motor and high gear ratio are used, then sufficient force is provided for opening under extreme conditions, but the device size and installation space requirements increase
Solution Approach 1:
The actuating device uses a compact design that provides high force in one rotation direction without requiring a large motor. The high force capability is achieved through the mechanical advantage of the lever arm and cable winch arrangement, not through a large motor, thereby reducing the volume of the device while maintaining reliability.
Solution Approach 2:
The cable winch acts as an intermediary mechanism between the compact actuator and the locking mechanism. It provides mechanical advantage to amplify the force from a compact actuator, eliminating the need for a large motor while still delivering sufficient force for opening under extreme conditions.
4Reliability
If high force is always applied to open the locking mechanism, then reliability is ensured under all conditions, but energy expenditure and time for opening increase during normal operation
Solution Approach 1:
The system dynamically switches between high-force and low-force modes based on the operational state. During normal operation, low force is applied for quick opening, minimizing time loss. When extreme conditions are detected, the system switches to high-force mode to ensure reliability. This dynamic adjustment resolves the contradiction by providing fast opening during normal conditions while maintaining reliability when needed.
Solution Approach 2:
The control unit changes the force parameter by selecting different rotation directions of the actuator. This parameter change allows the system to provide low force for quick opening during normal operation and high force for reliable opening under extreme conditions, thereby reducing time loss during normal operation while maintaining reliability when necessary.
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
Enables reliable opening of the locking mechanism with significantly lower energy expenditure in regular conditions and up to four times greater force when necessary, without requiring excessive technical effort or installation space, ensuring reliable operation even in exceptional situations.
Implementation Method 1
The cable winch is arranged in particular close to the axis of the rotatable actuator in order to be able to provide a lever ratio with a high transmission and thus great force
Implementation Method 2
The actuator is driven in particular at its outer circumference by a drive, in particular by an electric motor and gearbox
Implementation Method 3
The actuator is driven in particular at its outer circumference by a drive, in particular by an electric motor and gearbox
Data Source
Figure 1~2
AI summary
The object of the invention is to enable the locking mechanism of an electrically operated lock of a motor vehicle to be opened with sufficient force at all times, without requiring an excessively large electric motor and/or an excessively large gear ratio. To achieve this object, a lock for a motor vehicle comprises a locking mechanism and an actuating device for opening the locking mechanism. The actuating device includes a rotatable actuator that can be rotated by a motorized drive, in particular an electric drive. Rotating the actuator causes the locking mechanism to disengage, i.e., to open. The locking mechanism can be opened regardless of the direction of rotation of the actuator. Therefore, a specific direction of rotation is not required to open the locking mechanism. The force with which the locking mechanism is opened depends on the direction of rotation of the actuator.It can therefore be opened with varying force depending on the direction of rotation. This allows for opening with less force during normal operation compared to situations requiring more force. Under normal operating conditions, where a typical force is sufficient to open the lock, it can be opened quickly and with minimal energy expenditure. However, the option remains to open with greater force, albeit with a delay, when necessary.