Modular Plug-In Gearbox for Efficient Synchronous Actuators
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Solution Overview
Problem
Existing actuators with synchronous motors often operate outside their optimum range, leading to poor efficiency when varying rotational speeds are required.
Innovation Solution
A plug-in gearbox system with modular elements allows for adjustable gear ratios and direct output-wheel drive, enabling operation within an optimum range and improving motor efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a synchronous motor is used to control valve position, then the motor can operate at controlled rotational speeds, but the motor often operates outside its optimum range leading to poor efficiency
Solution Approach 1:
A gearbox is introduced as an intermediary mechanism between the synchronous motor and the valve. The gearbox transmits and modifies the motor's rotational motion, allowing the motor to operate at constant, optimal speeds while the gearbox handles the speed variation needed for different valve positions. This mediator resolves the conflict between maintaining motor efficiency and achieving variable output speeds.
Solution Approach 2:
The system changes the operational parameters by maintaining constant motor speed (optimal parameter) while using a gearbox with variable gear ratios to achieve different output speeds. The gearbox acts as a parameter transformation device, converting the motor's constant-speed operation into variable-speed output suitable for different valve positioning requirements.
2Loss of energy
If a gearbox is introduced to maintain optimal motor speeds, then motor efficiency improves, but the device complexity increases
Solution Approach 1:
The actuator is segmented into distinct functional modules: the synchronous motor unit, the gearbox unit, and the valve unit. This segmentation allows each component to be optimized independently - the motor operates in its optimal range while the gearbox provides the necessary speed transformation. The modular structure manages complexity by separating functions into manageable, interchangeable components.
Solution Approach 2:
The gearbox is designed as a universal component that can handle multiple gear ratio configurations to accommodate different valve types and positioning requirements. This multi-functional gearbox reduces overall system complexity by providing a single versatile solution rather than requiring different mechanisms for different applications.
3Loss of energy
If variable gear ratios are implemented, then motor efficiency is maintained across different operating conditions, but the quantity of components increases
Solution Approach 1:
The gearbox incorporates dynamically adjustable gear ratios that can be changed without completely disassembling the system. This dynamic capability allows the same physical gearbox structure to provide multiple gear ratio configurations, reducing the need for multiple separate components while maintaining motor efficiency across different operating conditions.
Solution Approach 2:
The gearbox design nests multiple gear mechanisms within a single integrated housing, allowing various gear ratio configurations to be achieved through internal component arrangements rather than requiring separate external components. This nesting approach minimizes the overall quantity of parts while providing variable gear ratio functionality.
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 system enables flexible adjustment of gear ratios to maintain constant motor-shaft speeds, reducing heat development and enhancing motor efficiency while minimizing space and component count.
Implementation Method 1
an actuator with a motor, in particular a synchronous motor
Implementation Method 2
The plug-in gearbox can thus be set up to provide different gear ratios through a modular system having at least several (multi-stage) plug-in elements
Implementation Method 3
a method for controlling a brake of an actuator
Data Source
AI summary
The invention relates to an actuator with a modular system for creating a plug-in gearbox, wherein the modular system comprises at least one output gear wheel and at least one plug-in element, and wherein a plug-in gearbox with one to five stages can be created by the modular system.