Dual-Drive Linear Actuator Failover for Jammed Shaft Motion
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Solution Overview
Problem
Rotary-to-linear actuators often fail due to jamming or component breakdown, leading to partial or complete prevention of linear movement, which can be critical in applications requiring continuous translation.
Innovation Solution
A linear actuator system with a dual drive system and control mechanism, where a secondary rotary component is activated upon failure of the primary drive system to ensure continued operation by allowing relative movement between shaft portions, enabling the actuator to switch to a backup mode and maintain functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single drive system is used in a rotary-to-linear actuator, then the device complexity is reduced, but the reliability deteriorates due to potential jamming or component breakdown preventing linear movement
Solution Approach 1:
The drive system is segmented into multiple independent rotary components (first rotary component and second rotary component) that can operate independently. Each rotary component has its own drive system, allowing one to fail without completely disabling the actuator. This segmentation increases reliability while managing complexity through modular design.
Solution Approach 2:
The second rotary component is positioned and prepared in advance as a backup, axially displaced from the first rotary component. When failure of the first drive system is detected, the second rotary component is already in position to take over, eliminating the need for complex real-time reconfiguration and maintaining system reliability with minimal added complexity.
2Reliability
If a dual drive system is implemented to prevent complete failure, then the reliability is improved, but the device complexity increases due to additional components and control mechanisms
Solution Approach 1:
The second rotary component is pre-positioned axially displaced from the first rotary component, ready to take over upon failure detection. This preliminary arrangement simplifies the control logic compared to systems requiring dynamic reconfiguration, as the backup component is already in the correct position to engage when needed.
Solution Approach 2:
The system dynamically switches between the first and second rotary components based on operational status. The control system monitors the first drive system and activates the second rotary component when failure is detected, creating a dynamic failover mechanism that improves reliability while managing complexity through adaptive control.
3Device complexity
If the second rotary component is positioned at the same axial location as the first, then the device complexity is reduced, but the reliability deteriorates because both components would interfere with each other during operation
Solution Approach 1:
The second rotary component is axially displaced from the first rotary component, preparing it in advance as a backup. This spatial separation prevents interference during normal operation of the first component while ensuring the second component is positioned to take over when needed, maintaining both simplicity and reliability.
Data Source
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AI summary
A linear actuator (100) arranged to convert rotary motion to linear motion is disclosed. The linear actuator includes a linear shaft arrangement, having a first shaft portion (110) and a second shaft portion (130) and extends along a longitudinal axis (A) of the linear actuator. At least one of the first shaft portion and the second shaft portion of the linear shaft arrangement can be translated linearly along the longitudinal axis upon actuation. A first drive system has a first rotary component (106) extending at least partially around the longitudinal axis. A second drive system has a second rotary component (126) extending at least partially around the longitudinal axis at a different axial position to the first drive system. The linear actuator, when the first drive system fails, allows rotation of the second rotary component so that the second shaft portion moves relative to the first shaft portion.