Dual-Sided Linear Actuator Assembly for EV Road Load Simulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current testing equipment for vehicle stability and durability lacks the capability to simulate real-world driving conditions, particularly for electric vehicles, as it fails to generate sufficient force and speed to mimic potholes and bumps effectively.
Innovation Solution
A high-speed linear actuator assembly comprising an actuator frame, armature, magnets, and linear motors that lift a vehicle off the ground and simulate road conditions by moving it in a pattern to mimic bumps and potholes, capable of handling the additional weight of electric vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional testing equipment is used, then the equipment structure is simple, but it cannot generate sufficient force and speed to simulate real-world driving conditions
Solution Approach 1:
The linear actuator is divided into distinct functional modules: a motor assembly generating rotational motion, a crank mechanism converting rotation to linear motion, and a piston-cylinder arrangement. This segmentation allows each component to be optimized for its specific function while collectively achieving high force and speed capabilities that conventional monolithic equipment cannot provide.
Solution Approach 2:
The actuator employs dynamic elements including a rotating crank that varies the mechanical advantage throughout the stroke cycle, and a piston system that can adjust force output based on operating conditions. This dynamic design enables the system to deliver peak forces at critical moments while maintaining high speed capability, resolving the contradiction between force generation and equipment simplicity.
2Speed
If conventional linear actuators are used, then the device is simple, but it cannot achieve high-speed operation required for simulating real road conditions
Solution Approach 1:
The crank mechanism utilizes curved rotational motion to convert continuous rotation into high-speed linear actuation. The circular path of the crank throw allows the piston to achieve rapid acceleration and high peak speeds during its stroke, enabling the actuator to simulate quick road imperfections like bumps and potholes at realistic velocities.
Solution Approach 2:
The actuator operates through periodic cycles of motor rotation, crank revolution, and piston reciprocation. This periodic action allows the system to repeatedly achieve high-speed strokes, maintaining consistent performance over time while the motor provides continuous rotational power. The cyclic nature enables high average speeds necessary for realistic road condition simulation.
3Force
If the actuator is designed to lift heavy electric vehicles, then the force capability increases, but the magnetic component dimensions increase
Solution Approach 1:
The magnetic components are designed with optimized parameters including high-energy-density magnetic materials that provide stronger flux density per unit volume. The magnet geometry and arrangement are parameter-optimized to maximize force output while minimizing volume, allowing the actuator to lift heavy electric vehicles without proportionally increasing magnetic material dimensions.
Solution Approach 2:
The actuator employs composite construction combining high-strength magnetic materials with optimized magnetic backing and yoke structures. This composite approach allows the magnetic circuit to efficiently channel flux with minimal material, achieving the required lifting force for heavy electric vehicles while keeping the magnetic component volume compact and manageable.
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 linear actuator assembly effectively simulates driving conditions, providing sufficient force to mimic real-world road scenarios, including potholes and bumps, and is capable of lifting and moving electric vehicles with their unique weight distribution, enhancing testing accuracy and realism.
Implementation Method 1
a first linear motor located on the first side of the armature and spaced apart from the one or more first magnets by a first air gap; and a second linear motor located on the second side of the armature and spaced apart from the one or more second magnets by a second air gap
Implementation Method 2
magnets comprising: a magnetic material that generates a magnetic field, the magnetic material comprising a magnetic material thickness
Implementation Method 3
a lifting assembly located within the one or more voids, the lifting assembly comprising: an air tank, and an air bag connected to and located axially above the air tank
Data Source
AI summary
A linear actuator assembly having: an actuator frame; an armature located within the actuator frame; magnets comprising: a magnetic material that generates a magnetic field, the magnetic material comprising a magnetic material thickness, and magnetic backing connected to the magnetic material comprising a magnetic backing thickness, wherein the magnets comprise: one or more first magnets connected to the first side of the armature, and one or more second magnets connected to the second side of the armature; a linear motor located on the armature and spaced apart from the first magnets by a first air gap; and a second linear motor located on the armature and spaced apart from the second magnets by a second air gap; and wherein the magnetic backing thickness is less than the magnetic material thickness; and wherein the armature, the first magnets, and the second magnets are moved relative to the actuator frame.