Helical Drive Electronic Lock Actuator for Wear Reduction
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Solution Overview
Problem
Existing electronic lock actuators often inefficiently distribute force and energy, leading to wear and mechanical issues due to focused force on small areas of the coupler spring, and may trap debris, affecting reliability and longevity.
Innovation Solution
A dual-spring actuator assembly with a motor shaft and coupler spring, where the drive member is threadably engaged with the coupler spring's end, allowing even force distribution and reduced stress, and featuring a helical drive surface that contacts multiple coils for linear displacement of the lock member between locked and unlocked positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If force is focused on small areas of the coupler spring, then the actuator can achieve sufficient mechanical force, but wear increases and mechanical issues occur
Solution Approach 1:
The drive member is segmented into multiple helical drive surfaces that engage with different sections of the coupler spring simultaneously. This distributes the applied force across multiple contact points rather than concentrating it on a single small area, reducing wear on any one point while maintaining sufficient total mechanical force.
Solution Approach 2:
The invention transitions from a single-point or single-line force application to a distributed surface contact mechanism. The helical drive surfaces create multiple contact zones along the length of the coupler spring, effectively adding a dimensional aspect to force distribution that spreads the mechanical load across a larger volume of the spring structure.
2Ease of operation
If traditional drive mechanisms are used, then the lock member can be displaced, but debris may be trapped affecting reliability
Solution Approach 1:
The helical drive surface design extracts the problematic debris-trapping enclosed spaces from the mechanism. The open helical structure allows debris to pass through or be ejected during operation, rather than being trapped in enclosed gaps between drive components and the coupler spring.
Solution Approach 2:
The drive member incorporates a porous or open-helical structure that allows debris particles to pass through the drive mechanism rather than being trapped. This porous-like geometry maintains mechanical functionality while providing a self-cleaning effect that prevents debris accumulation.
3Productivity
If force is concentrated on small areas, then mechanical action is efficient, but stress on the coupler spring increases
Solution Approach 1:
The coupler spring engagement is segmented into multiple sections that are contacted simultaneously by different portions of the helical drive surfaces. This segmentation distributes the total force across multiple spring sections, reducing the stress concentration on any single section while maintaining overall mechanical efficiency through coordinated action of all segments.
Solution Approach 2:
The helical drive surfaces are configured to gradually engage multiple sections of the coupler spring in a controlled sequence, applying force progressively rather than suddenly. This preliminary distribution of force prevents stress shocks and reduces peak stress levels while maintaining efficient force transmission throughout the spring.
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 dual-spring design enhances energy absorption, reduces stress on the coupler spring, minimizes wear, and prevents mechanical binding, while being self-cleaning and cost-effective, improving the reliability and durability of electronic lock actuators.
Implementation Method 1
A drive member is either coupled with, or integrally formed with, the motor shaft and has a helical drive surface threadably engaged with the coupler spring second end. As such, rotation of the motor shaft displaces the coupler spring generally linearly along the axis to move the lock member between the locked and unlocked positions.
Data Source
AI summary
An actuator assembly is for a lock including a handle, a latch, a retractor for retracting the latch when the handle rotates, and a lock member displaceable between locked and unlocked positions, which either releasably couples the handle with the retractor or releasably prevents handle rotation. The actuator includes a motor having a shaft rotatable about an axis and a coupler spring disposed about the axis and having a first end coupled with the lock member and a second end. A drive member is coupled or integrally formed with the motor shaft and has a helical drive surface threadably engaged with the coupler spring second end, such that rotation of the shaft displaces the coupler spring along the axis to move the lock member between the locked and unlocked positions. Preferably, the drive member includes a spring coupled with the motor shaft and threadably engaged with the coupler spring.