L-Shaped Bowden Cable Connector for Motor Vehicle Lock Actuator
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Solution Overview
Problem
Existing actuating units for motor vehicle locks with Bowden cables face issues with high forces exceeding the mechanical limits of connection parts, often requiring microswitches for movement limitation, which increase manufacturing costs and space requirements.
Innovation Solution
An angular or L-shaped connection part is used to stabilize the Bowden cable connector, distributing forces over a large area and eliminating the need for microswitches, with a press connection and metal components enhancing mechanical stability, and a simplified design that includes a one-piece housing and screw connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional connection part is used to connect the Bowden cable to the actuator housing, then the structure is simple, but it cannot withstand high forces (typically approx. 250 N) without microswitch limitations
Solution Approach 1:
The connection part transitions from a simple linear or planar structure to a three-dimensional angular/L-shaped configuration. This dimensional change allows the connection part to engage with the actuator housing in multiple directions, distributing forces across a larger volume and improving load-bearing capacity without adding complex assembly mechanisms.
Solution Approach 2:
The connection part is formed as an integrated component combining structural elements that interface with both the Bowden cable and the actuator housing. This composite structure integrates multiple functional requirements (force transmission, mounting attachment, cable guidance) into a single load-optimized component, enabling it to withstand high forces without requiring additional reinforcing elements or microswitches.
2Reliability
If microswitches are used to limit actuator movement, then the actuator movement can be controlled, but manufacturing costs increase and installation space is required
Solution Approach 1:
The actuator housing and connection part are designed to provide inherent mechanical limits to actuator movement through their geometric configuration. The angular connection part and housing structure create natural stop positions that prevent over-travel without requiring external control devices. This self-limiting mechanism eliminates the need for microswitches while maintaining reliable movement control.
Solution Approach 2:
The microswitches and associated electronics are completely removed from the system. The movement control function previously performed by microswitches is transferred to the mechanical structure of the connection part and housing, which provide passive geometric constraints on actuator travel. This extraction simplifies manufacturing and reduces costs while maintaining the essential control function.
3Reliability
If microswitches and associated electronics are installed to limit actuator movement, then movement control is achieved, but weight increases
Solution Approach 1:
The structural components (connection part and housing) perform the dual function of force transmission and movement limitation. By designing the geometry of these components to provide natural mechanical stops, the system eliminates the need for separate microswitches and electronics, thereby reducing the overall weight of the actuating unit while maintaining reliable movement control.
4Ease of manufacture
If the actuator movement is limited by the connection part instead of a microswitch, then manufacturing costs are reduced and space is saved, but high forces must be withstood by the connection part
Solution Approach 1:
The connection part adopts a three-dimensional angular/L-shape configuration that allows it to distribute high forces across multiple engagement surfaces with the actuator housing. This dimensional complexity enables the component to handle approximately 250 N of force while maintaining a relatively simple overall structure that eliminates the need for microswitches.
Solution Approach 2:
The connection part is designed as an integrated composite structure that combines multiple functional elements (force transmission path, mounting interface, cable guidance) into a single load-optimized component. This integration allows the structure to be tailored for high strength where needed while maintaining cost-effectiveness by eliminating separate components.
Data Source
Figure 1~2
AI summary
The invention relates to an actuating unit for a motor vehicle lock, comprising a motor element and a drive for moving the motor element, a Bowden cable connected to the motor element and a connecting element for the Bowden cable. The invention further relates to a method of production. The aim of the invention is to simplify production of an actuating unit having a Bowden cable. According to the invention, the connecting element for the Bowden cable is angular, especially L-shaped, and a leg thereof, in the case of an L shape preferably the long leg thereof, is connected to the remainder of the housing. The angular form or L shape and the connection of one leg of such a shape to the remainder of the housing of the motor element results in a large surface or a large peripheral edge of the connecting part which can be connected to the remainder of the housing. As a result, the connecting element can be firmly secured to the remainder of the housing such that the latter withstands the forces of a motor element even when the movement of the motor element is not limited with the aid of a microswitch but with the aid of the connecting element.