Long Rail Assembly With Internal Drive to Block Debris Exposure
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Solution Overview
Problem
Existing vehicle seat adjustment systems are prone to inefficiency and failure due to dirt and debris accumulation on mechanical parts, which are often exposed and unprotected.
Innovation Solution
A long rail assembly with a lower and upper channel, gears, rack, pinion, and motor configuration that conceals mechanical parts from debris, using a worm gear mechanism to power seat adjustment, with optional flexible or direct shaft connections for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical parts are exposed for easy access and maintenance, then ease of operation is improved, but reliability deteriorates due to dirt and debris accumulation
Solution Approach 1:
The mechanical components (rack, pinion, gears) are nested within the channel structure, with the rack positioned in the lower channel and the pinion/gear assembly positioned in the upper channel. This nesting protects the components from external contaminants while maintaining structural integration and accessibility for maintenance.
Solution Approach 2:
The channel walls act as an intermediary barrier between the mechanical components and the external environment (dirt, debris). The lower channel houses the rack while the upper channel houses the drive mechanism, creating a protective intermediary structure that prevents direct contact with contaminants.
2Reliability
If mechanical parts are sheltered from dirt and debris, then reliability is improved, but ease of operation worsens due to reduced accessibility
Solution Approach 1:
The mechanical components are nested within the channel structure, with the rack positioned in the lower channel and the pinion/gear assembly positioned in the upper channel. This nesting protects the components from external contaminants while maintaining structural integration and accessibility for maintenance.
Solution Approach 2:
The system is segmented into distinct functional zones: the lower channel containing the rack, the upper channel containing the drive mechanism, and the connection between them. This segmentation allows independent access to different components for maintenance while maintaining overall system protection.
3Ease of operation
If the rack is positioned facing upward for easy access, then ease of operation is improved, but object-affected harmful factors worsen due to direct exposure to debris
Solution Approach 1:
Instead of positioning the rack teeth facing upward for accessibility, the rack is positioned with teeth facing downward into the lower channel. This inversion protects the rack from debris accumulation while maintaining mechanical functionality through the channel structure.
Solution Approach 2:
The mechanical components (rack, pinion, gears) are nested within the channel structure, with the rack positioned in the lower channel and the pinion/gear assembly positioned in the upper channel. This nesting protects the components from external contaminants while maintaining structural integration and accessibility for maintenance.
4Device complexity
If a direct shaft connection is used for power transmission, then device complexity is reduced, but loss of energy increases due to less efficient torque transmission
Solution Approach 1:
The patent replaces a simple direct shaft connection with a worm gear mechanism. The worm gear provides mechanical advantage for torque multiplication and includes self-locking characteristics that prevent backdriving, improving energy efficiency despite increased mechanical complexity.
Solution Approach 2:
The worm gear acts as an intermediary mechanism between the motor and the rack/pinion system. It provides torque multiplication and directional control, mediating the power transmission more efficiently than a direct shaft connection while adding controlled complexity to the drive system.
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
Protects mechanical components from dirt and debris, maintaining system efficiency and functionality by preventing direct contact with contaminants, and allowing for adjustable seat positioning with enhanced torque and speed control.
Implementation Method 1
A long rail assembly with a lower and upper channel, gears, rack, pinion, and motor configuration that conceals mechanical parts from debris, using a worm gear mechanism to power seat adjustment
Implementation Method 2
The pinion is meshingly engaged with the gear teeth. The drive shaft operatively couples the plurality of gears to the pinion.
Data Source
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AI summary
A long rail assembly for use in a vehicle includes a lower channel, an inverted U-shaped upper channel, a gearbox, a rack, a pinion, a drive shaft, and a motor. The lower channel is adapted to extend longitudinally along a floor of the vehicle. The upper channel is slidably coupled to the lower channel. The gearbox is fixedly secured to and housed within the upper channel. The rack is fixedly coupled to the lower channel and includes gear teeth extending along the rack in a longitudinal direction. The pinion is meshingly engaged with the gear teeth. The drive shaft operatively couples the gearbox to the pinion. The motor is operatively coupled to the gearbox to power drive the upper channel along the lower channel.