Long Rail Assembly With Internal Drive to Block Dirt Buildup
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power-adjustable seat systems in vehicles suffer from inefficiency and failure due to dirt and debris accumulation on mechanical parts, which are not adequately protected from the vehicle floor.
Innovation Solution
A long rail assembly comprising a lower channel, an inverted U-shaped upper channel, a gearbox, a rack, a pinion, and a motor, where the gearbox is secured within the upper channel, the rack is mounted within the lower channel with gear teeth facing downwards, and the pinion is vertically oriented to prevent dirt accumulation, with a motor-driven system that includes a flexible shaft for efficient power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical parts are integrated with the vehicle floor for power seat adjustment, then the system can achieve power adjustment functionality, but dirt and debris accumulate on the mechanical parts causing inefficiency and failure
Solution Approach 1:
The mechanical components (gearbox, rack, pinion) are nested within the channel structure. The upper channel is slidably coupled to the lower channel, creating a nested configuration where the mechanical parts are housed inside the channel, protecting them from dirt and debris on the vehicle floor while maintaining power adjustment functionality
Solution Approach 2:
The mechanical components are extracted from direct contact with the vehicle floor and placed inside the protected channel environment. This separation removes the harmful exposure to dirt and debris while preserving the power adjustment capability
2Ease of manufacture
If mechanical parts are exposed to the vehicle floor for ease of installation and maintenance, then accessibility is improved, but dirt and debris cause the system to become less efficient or stop working
Solution Approach 1:
The channel structure provides a nested housing for the mechanical components, allowing them to be installed as an integrated unit while protecting them from environmental contaminants during operation
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 solution effectively shields mechanical components from dirt and debris, ensuring reliable and efficient operation of the seat adjustment system by preventing dirt accumulation on the gearbox, rack, and pinion, thereby maintaining system performance.
Implementation Method 1
The pinion is meshingly engaged with the gear teeth
Implementation Method 2
The motor is operatively coupled to the gearbox to power drive the upper channel along the lower channel
Implementation Method 3
The drive shaft operatively couples the gearbox to the pinion
Data Source
Figure 1
Figure 2
Figure 3
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.