Linear Actuator Rail Bracket to Prevent Bolt Shear Failure
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Solution Overview
Problem
The existing flats sequencing system linear actuators experience bolt failure due to excessive downward force, leading to system downtime and potential damage, as the bolts are overwhelmed by parallel shearing forces and vibration, causing fatigue and fracture.
Innovation Solution
The implementation of a support bracket system that distributes the downward force from the guide rails to the frame member, using additional bolts or protrusions to alleviate the shearing stress on the attaching bolts, thereby reducing the load on individual bolts and extending their lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bolts are used to attach guide rails to the frame member, then the linear actuator can be assembled and function, but the bolts fail due to excessive downward force and parallel shearing forces
Solution Approach 1:
The support structure is divided into multiple segments: the frame member, the guide rail, and an intermediate support bracket. The bracket segments the force transmission path, allowing the downward force to be distributed to multiple attachment points on the frame member rather than concentrated on single bolts attaching the guide rail directly.
Solution Approach 2:
An intermediate support bracket is introduced between the guide rail and the frame member. This intermediary component receives the downward force from the guide rail and distributes it to the frame member through multiple attachment points, preventing excessive stress on the guide rail attachment bolts.
2Reliability
If additional support brackets are added to distribute force, then bolt failure is prevented, but the device complexity increases
Solution Approach 1:
The support bracket serves multiple functions: it provides structural support for the guide rail, distributes downward forces to the frame member, and acts as a force-mitigating element. This multi-functionality reduces the need for additional specialized components, minimizing the increase in overall device complexity.
Solution Approach 2:
The support bracket combines several functions into a single component: structural support, force distribution, and attachment to the frame member. By merging these functions into one element rather than using separate components for each function, the increase in device complexity is minimized.
Data Source
AI summary
A system of mitigating force in a mechanical system, the system comprising a frame member, a first rail connected to the frame member, a second rail connected to the frame member and extending along the frame member in parallel to the first rail, an assembly movably engaging the first and second rails, and a first bracket located between the first and second rails, with at least one first bracket attachment secured to the frame member, the first bracket sharing an upper edge with a lower edge of the first rail, such that a downward force applied on the first rail is distributed to the first bracket and the frame member via the at least one first bracket attachment.