Heavy-Load Linear Actuator Bearing Structure for Thin Gearbox Covers
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Solution Overview
Problem
Existing industrial heavy load electric linear actuators face limitations due to weak gearbox covers made of plastic or die-casting materials, restricting the maximum acceptable load and increasing ineffective distance when attempting to enhance load capacity.
Innovation Solution
The industrial heavy load electric linear actuator incorporates a load bearing structure comprising a sleeve, bearing, fastening element, fixation seat, and rear supporting seat, which allows the actuator to bear maximum loads while maintaining a thin gearbox cover for reduced material costs and distance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the gearbox cover is increased to increase its strength, then the load-bearing capacity is improved, but the ineffective distance is increased and material cost increases
Solution Approach 1:
The patent divides the load-bearing function into two separate components: the gearbox cover (which provides structural enclosure) and the load bearing structure (which provides mechanical support). The load bearing structure includes a sleeve mounted on the lead screw, a bearing for support, and fastening elements, separating the functions of enclosure and load-bearing to allow the cover to remain thin while still achieving high load capacity.
2Strength
If the thickness of the gearbox cover is increased to increase its strength, then the load-bearing capacity is improved, but the material cost is increased
Solution Approach 1:
The patent separates the load-bearing function from the gearbox cover by introducing a dedicated load bearing structure with a sleeve, bearing, and fastening elements. This allows the cover to be made from thinner, less expensive material while the load-bearing components (particularly the bearing and sleeve) handle the mechanical stresses, reducing overall material cost.
3Quantity of substance
If the gearbox cover is made from plastic or die-casting material to reduce cost, then the material cost is reduced, but the load-bearing capacity is restricted
Solution Approach 1:
The patent uses plastic or die-casting material for the gearbox cover to reduce cost, but introduces a separate load bearing structure with a sleeve, bearing, and fastening elements to handle the load-bearing requirements. This segmentation allows each component to be optimized for its specific function: the cover for cost-effective enclosure and the load bearing structure for mechanical strength.
Solution Approach 2:
The load bearing structure acts as an intermediary between the lead screw and the gearbox cover. The sleeve mounted on the lead screw transfers loads through the bearing to the fixation seat and rear supporting seat, which are connected to the gearbox cover. This intermediary structure protects the plastic or die-casting cover from direct load stress while still achieving high load-bearing capacity.
4Reliability
If a braking mechanism is added to prevent locking failure under heavy load, then the reliability is improved, but the device complexity is increased
Solution Approach 1:
The patent combines the braking mechanism with the existing gearbox structure, arranging it inside the gearbox on one lateral side of the driving gear. This integration allows the braking function to be added without requiring a completely separate mechanism, thereby improving locking reliability while minimizing the increase in overall device complexity.
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 load bearing structure effectively transmits loads through the lead screw and bearing, preventing locking failures and maintaining appropriate length, thereby enhancing the actuator's load-bearing capacity and reducing material and space inefficiencies.
Implementation Method 1
The sleeve is mounted to the lead screw and holds the bearing jointly with the fastening element
Data Source
AI summary
An industrial heavy load electric linear actuator includes a gearbox, an electric motor, a lead screw, an extension pipe and a load baring structure. The electric motor is connected to the gearbox. A portion of the lead screw is received inside the gearbox and driven by the electric motor, and another portion of the lead screw is extended out of the gearbox. The extension pipe is movably fastened to the lead screw. The load bearing structure includes a sleeve, a bearing, a fastening element, a fixation seat, and a rear supporting seat. The sleeve is mounted to the lead screw and holds the bearing jointly with the fastening element. The fixation seat and the rear supporting seat hold the bearing at outer perimeters of the sleeve and the fastening element.