Actuator Assembly for Mirror Head Using Magnetic Coupling
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Solution Overview
Problem
Conventional external rearview mirrors face issues with ride quality due to an outboard center of gravity, require substantial manual adjustment efforts, and suffer from durability problems and noise due to exposed clutch mechanisms and inadequate structural support, leading to vibration of the mirror glass.
Innovation Solution
An actuator assembly with a tubular member, inner and outer carriages, a helix drive shaft, and a motor drive, utilizing magnetic coupling between neodymium or samarium-cobalt magnets to achieve telescoping motion, with an anti-rotation feature and roller assemblies for smooth operation, and a gear train for efficient power transmission, which shifts the center of gravity inboard and protects components from environmental damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional motor and gear set actuators are used with outboard clutch mechanisms, then manual override capability is achieved, but the center of gravity is positioned too far outboard which deteriorates ride quality
Solution Approach 1:
The patent replaces the conventional mechanical clutch mechanism with a magnetic coupling system. The magnetic coupling allows manual override by simply pulling the mirror head away from the vehicle body, eliminating the need for complex mechanical clutch components located outboard. This substitution moves the center of gravity inboard, improving ride quality while maintaining manual override capability.
2Strength
If helix drive mechanism is used for telescoping action, then structural support is improved, but exposed clutch or slip-nut mechanisms are required for manual operation which reduces durability due to environmental ingress
Solution Approach 1:
The patent replaces exposed mechanical clutch or slip-nut mechanisms with an enclosed magnetic coupling system. The magnetic coupling between the drive shaft and the mirror head assembly is completely enclosed, preventing ingress of dirt and debris from the environment. This maintains the structural support benefits of the helix drive while eliminating durability issues associated with exposed manual override mechanisms.
3Productivity
If conventional electric powered telescoping mirrors are used, then telescoping action is achieved, but adverse effects occur including actuator motor noise, gear whine, and excessive over-ride forces
Solution Approach 1:
The patent replaces the conventional electric motor and gear set with a magnetic coupling system. The magnetic coupling eliminates mechanical contact between the drive shaft and the mirror head assembly, thereby eliminating noise and vibration generated by motor operation and gear engagement. This substitution maintains telescoping functionality while eliminating harmful noise and vibration effects.
4Device complexity
If less structural support is provided for the mirror head, then device complexity is reduced, but mirror glass vibration increases
Solution Approach 1:
The patent replaces complex mechanical support structures with a magnetic coupling system. The magnetic coupling provides sufficient structural support to prevent mirror glass vibration while maintaining a simple, lightweight design. The magnetic field provides continuous support without the need for complex mechanical linkages or additional structural components.
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 provides improved ride quality, reduced manual adjustment effort, quieter and smoother operation, and enhanced durability by enclosing drive components and utilizing magnetic coupling for efficient power transfer, while maintaining ergonomic and structural support for the mirror system.
Implementation Method 1
The outer carriage includes one or more outer magnets magnetically coupled to the one or more inner magnets of the inner carriage
Data Source
AI summary
The present disclosure provides an actuator assembly for a mirror head. The actuator includes a tubular member, an inner carriage, an outer carriage, a helix drive shaft and a motor drive. The inner carriage includes one or more inner magnets. The outer carriage is coupled to the mirror head. The outer carriage includes one or more outer magnets magnetically coupled to the one or more inner magnets of the inner carriage. The helix drive shaft is drivably coupled to the inner carriage. The motor drive is configured to rotate the helix drive shaft relative to the tubular member. Upon rotation of the helix drive shaft by the motor drive, the inner carriage translates. The outer carriage also translates along with the inner carriage due to magnetic coupling between the one or more inner magnets and the one or more outer magnets.