Linear Actuator End Stop Assembly With Snap-On Control Box
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Solution Overview
Problem
Traditional linear actuators have complex and costly end stop arrangements due to the need for extensive wiring and large printed circuit boards, and they lack a simple and secure method for connecting the control box, which can lead to damage when the spindle nut reaches its end position.
Innovation Solution
A linear actuator design featuring a snap connection between the control box and the console, along with a sliding element that activates end switches only when the spindle nut reaches its stroke limit, allowing for a compact printed circuit board and easier assembly, and enabling the use of different end stop switches without altering the actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the control box is connected to the linear actuator using brackets and clips, then the connection is secure, but the device complexity and assembly cost increase
Solution Approach 1:
The control box is integrated directly with the console housing to form a single unified component, eliminating the need for separate brackets and clips. This merging of components simplifies the overall structure while maintaining secure connection, as the control box becomes an inherent part of the console assembly rather than an attached accessory.
Solution Approach 2:
The console housing serves multiple functions: it provides structural support, houses the control box, and eliminates the need for separate mounting brackets. By making the console housing multi-functional, the design reduces the number of individual parts required while maintaining structural integrity and connection security.
2Reliability
If the end switches are mounted on a printed circuit board, then the electrical connection is stable, but the printed circuit board requires considerable length and takes up much space inside the outer tube
Solution Approach 1:
The end switches are extracted from the traditional printed circuit board mounting arrangement and repositioned to be directly mounted on the console housing. This extraction from the PCB reduces the required PCB length and frees up space inside the outer tube, while the switches remain electrically connected through alternative wiring paths.
Solution Approach 2:
Instead of mounting the end switches in a linear arrangement along the length of the printed circuit board, the switches are repositioned to utilize the three-dimensional space on the console housing surface. This dimensional reorganization allows for compact switch placement that reduces the required PCB length while maintaining electrical connectivity.
3Volume of moving object
If the end stop arrangement is integrated in the housing or cabinet, then the construction is compact, but the assembly process becomes complex and costly
Solution Approach 1:
The end stop arrangement is segmented into separate, modular components that can be independently manufactured and then assembled. This segmentation allows each component to be produced using simpler, more cost-effective processes while maintaining the compact integrated appearance when assembled together, reducing overall assembly complexity and cost.
Solution Approach 2:
The end stop components are pre-assembled and pre-positioned during the manufacturing process rather than being installed during final assembly. This preliminary action allows for more precise positioning and simpler final assembly, reducing assembly complexity and cost while maintaining the compact integrated construction.
Data Source
AI summary
The present invention relates to a linear actuator comprising a console, an outer tube connected to the console, an electric motor, a transmission, and a spindle in connection with the transmission. The linear actuator comprises a spindle nut on the spindle and an inner tube connected to the spindle nut. The spindle nut and the inner tube are guided inside the outer tube. The linear actuator comprises a control box which is connected to the console by means of a snap connection. The linear actuator further comprises an end stop arrangement having an end switch for each direction of movement of the spindle nut. An object underlying the invention is to provide a simpler connection of the control box to the linear actuator. A further object is to provide a less complex construction of the end stop arrangement of a linear actuator. To this end, the control box is connected to the console by means of a snap connection. Further, the linear actuator comprises a sliding element arranged between the spindle nut and the end switches, and where the sliding element is actuated by the spindle nut.