Encoder Coaxial Alignment for Bed Lift Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing bed handling systems in vehicles like campers lack a reliable and efficient control mechanism for electric actuators that operate the winding/unwinding of bed base lifting/lowering belts, leading to complex installations and high production costs.
Innovation Solution
A control device with an encoder directly connected to the gearmotor output, eliminating intermediate transmissions, ensuring precise angular position detection and simplified installation by using a rigid tubular body to align the encoder rotor coaxially with the gearmotor output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an encoder is installed in a conventional configuration with intermediate transmissions, then the control function is provided, but the device complexity increases and reliability decreases
Solution Approach 1:
The encoder is extracted from the conventional configuration with intermediate transmissions and directly coupled to the gearmotor output. This removes the intermediate transmission components, simplifying the device structure and improving reliability by eliminating potential failure points in the transmission chain.
Solution Approach 2:
The encoder and gearmotor are merged into a single integrated unit where the encoder rotor is directly coupled to the gearmotor output shaft. This combination eliminates the need for separate mounting and intermediate transmissions, reducing device complexity while maintaining precise control functionality.
2Reliability
If intermediate transmissions are used between the encoder and gearmotor, then the control function is achieved, but the production costs increase
Solution Approach 1:
The intermediate transmission components are extracted from the system, leaving only the direct coupling between encoder and gearmotor. This reduction in component count lowers production costs while maintaining the essential control function through the direct connection.
3Ease of operation
If the encoder is installed with intermediate transmissions, then the control function is provided, but the installation time and accessibility increase
Solution Approach 1:
The encoder and gearmotor are merged into a single assembly unit that is pre-configured with direct coupling. This integration allows the entire control unit to be installed as one component, significantly reducing installation time and improving accessibility to adjustment members and wiring.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
Control device for bed handling systems installed in vehicles such as campers and similar so-called recreational vehicles comprising a gearmotor (2) which controls the rotation of a shaft (7) on which are constrained belts (1) to which a bed base (3) is connected, wherein the rotation of the shaft (7) controlled by the gearmotor (2) in one direction or in the opposite direction determines the lifting or lowering of the bed base (3) by means of the belts (1), and wherein there is an encoder (10) configured to detect one or more parameters related to the rotation of said shaft (7). Said encoder has a rotor (101) and a stator (102). The rotor (101) of the encoder is arranged coaxially with an output (27) of the gearmotor (2) and with said shaft (7).