Compact Gear Motor Angular Stator Vibration Resistance
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Solution Overview
Problem
Existing mechatronic actuators for motor vehicle components, such as air vents and valve shutters, face issues with excessive space requirements and inadequate vibration and shock resistance, leading to potential disassembly of components due to vibrations.
Innovation Solution
A mechatronic actuator design featuring a radial triangular star-shaped stator with a three-phase electric motor, a gear train, and an electronic circuit with a filtering capacitor, optimized for space usage by positioning the stator at a specific angle within the housing, and incorporating a metal spring for grounding and a cover with stops to prevent unintended movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional actuator designs are used, then the basic motor functions are achieved, but the space requirements become excessive and internal volume is not maximized
Solution Approach 1:
The stator is repositioned from a conventional axial alignment to an angular orientation (70-110 degrees relative to the longitudinal axis), transforming the spatial arrangement from a standard linear layout to an angular configuration. This dimensional change allows more efficient packing of components within the housing, maximizing internal volume occupancy while reducing overall actuator footprint.
Solution Approach 2:
The angular positioning of the stator creates optimized nesting arrangements where the capacitor can be positioned in the space between stator poles, and where intermediate toothed wheels are arranged to efficiently occupy available space. This nested arrangement allows multiple components to share the same volumetric envelope, reducing overall actuator dimensions.
2Reliability
If conventional actuator designs are used, then motor operation is maintained, but vibration and shock resistance is insufficient causing component disassembly
Solution Approach 1:
The housing incorporates stops that preemptively prevent excessive movement of the printed circuit and other components during vibration or shock events. These stops act as pre-positioned mechanical limits that cushion against the full force of vibrations, preventing component disassembly before it can occur.
Solution Approach 2:
The angular positioning of the stator (70-110 degrees) creates a structural configuration that inherently resists vibration-induced loosening. This preliminary angular arrangement optimizes the distribution of vibrational forces across the housing structure, preventing the cumulative effect that would otherwise cause component failure.
3Volume of moving object
If the stator is positioned at conventional angles, then manufacturing is simplified, but space optimization and vibration resistance are compromised
Solution Approach 1:
The stator positioning parameter is changed from a conventional axial angle (0 degrees) to an optimized angular range (70-110 degrees). This parameter change simultaneously achieves multiple objectives: maximizing space utilization, enabling capacitor placement in previously unusable spaces, and improving vibration resistance. The specific angular range provides an optimal balance between space optimization and manufacturability.
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 design reduces overall dimensions, maximizes internal space occupancy, enhances vibration resistance, and ensures reliable component attachment, preventing accidental disassembly and improving positioning accuracy.
Implementation Method 1
a three-phase electric motor formed by a stator excited by electric coils and by a magnetic rotor
Implementation Method 2
an electronic circuit comprising a capacitor for filtering the electrical signal
Data Source
AI summary
The present disclosure relates to a mechatronic actuator consisting of a housing incorporating a shell and a three-phase electric motor formed by a stator excited by electrical coils and by a magnetized rotor, driving an output shaft by means of a gear train, the axis of the rotor, the axis of the output shaft and the axes of the intermediate toothed wheels being parallel, the stator having a radial triangular star shape, the three wound poles forming the three branches of the star, the axes of symmetry of two consecutive wound poles forming a mechanical angle of 120°, the housing also incorporating an electronic circuit, including a capacitor for filtering the electrical signal, the shell having a longitudinal axis, characterized in that the stator is positioned in the hosing in such a way that the axis of symmetry of one of the three wound poles forms an angle of between 70 and 110° with the longitudinal axis.