Modular Actuator Assembly via Segmented Worm Drive Modules
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Solution Overview
Problem
Conventional linear actuators have complex structures and time-consuming assembly processes, which are costly and inefficient, especially in small-size electronic products where miniaturization is necessary to save space and reduce costs.
Innovation Solution
A modular actuator design comprising an actuation module, a gear module, and a telescoping module, where the actuation module includes a motor and drive worm, the gear module features a modularized deceleration gear assembly, and the telescoping module uses a drive worm gear engaged with a deceleration worm, allowing for simplified assembly by engaging these components directly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional linear actuator includes many parts inside with a gearbox and deceleration gear assembly, then the actuator can achieve the required mechanical advantage and speed reduction, but the assembling process becomes time-consuming and costly
Solution Approach 1:
The actuator is divided into three independent modular units: actuation module (motor + drive worm), gear module (deceleration gear assembly), and telescoping module (lead screw + extendable pipe). Each module can be manufactured and tested separately, then assembled by simple engagement, dramatically reducing overall assembly time while maintaining the required mechanical advantage through the preserved gear train configuration.
Solution Approach 2:
The patent combines the motor and drive worm into a pre-assembled actuation module, and the deceleration gear assembly into a separate gear module that can be engaged directly. This merging of components into functional modules eliminates the need for separate assembly of individual parts during final assembly, reducing assembling time and complexity while maintaining the complete mechanical advantage function.
2Reliability
If a conventional linear actuator includes many parts inside with complex assembly, then the actuator can achieve complete functionality, but the production costs increase due to time-consuming and problematic assembly
Solution Approach 1:
By segmenting the actuator into three functional modules with standardized interfaces, each module can be manufactured with high reliability in controlled environments and then assembled through simple engagement. This segmentation reduces assembly complexity and potential assembly errors while maintaining complete actuator functionality through the coordinated operation of modular components.
Solution Approach 2:
The patent changes the assembly parameter from complex multi-step procedures to simple engagement operations. The modular design with standardized interfaces allows modules to be connected through straightforward mechanical engagement rather than complex fastening procedures, significantly reducing assembly complexity while ensuring reliable functionality through precise modular interfaces.
3Volume of moving object
If the linear actuator is miniaturized for small-size electronic products, then space and costs are saved, but the structural complexity and assembly difficulties increase
Solution Approach 1:
The miniaturized actuator is segmented into three compact modules that can be arranged in series along a single axis. This segmentation allows each module to be optimized for minimal volume while maintaining its function, and the overall structure remains simple despite the reduced size, as the modules connect through straightforward engagement rather than complex internal arrangements.
4Volume of moving object
If the linear actuator is miniaturized for small-size electronic products, then space is saved, but the assembling problems increase
Solution Approach 1:
The miniaturized actuator is divided into three small-scale modules with standardized engagement interfaces. This segmentation allows each module to be manufactured with precision for compact dimensions while the assembly process remains simple, as the modules connect through straightforward mechanical engagement rather than complex procedures, thereby maintaining ease of manufacture despite the reduced size.
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
This modular design significantly reduces assembly time and costs by eliminating the need for separate assembly of motor and drive worm gear components, enhancing the practicality and efficiency of the actuator's production process.
Implementation Method 1
The deceleration gear assembly includes a deceleration worm gear engaged with the drive worm and includes a deceleration worm driven to rotate by the deceleration worm gear
Implementation Method 2
The gear module includes a gearbox and a deceleration gear assembly disposed in the gearbox
Implementation Method 3
The telescoping module includes a drive worm gear, a lead screw driven to rotate by the drive worm gear, and an extendable pipe threadedly connected to the lead screw
Implementation Method 4
The actuation module includes a motor and a drive worm driven by the motor
Data Source
AI summary
A modular actuator (1) includes an actuation module (10), a gear module (20) and a telescoping module (30). The actuation module (10) includes a motor (11) and a drive worm (12) driven by the motor (11). The gear module (20) includes a gearbox (21) and a deceleration gear assembly (22) disposed in the gearbox (21). The deceleration gear assembly (22) includes a deceleration worm gear (221) engaged with the drive worm (12) and includes a deceleration worm (222) driven to rotate by the deceleration worm gear (221). The telescoping module (30) includes a drive worm gear (31), a lead screw (32) driven to rotate by the drive worm gear (31), and an extendable pipe (33) threadedly connected to the lead screw (32). The drive worm gear (31) is engaged with the deceleration worm (222), and the lead screw (32) is arranged parallel to the drive worm (13).