Modular Linear Actuator Support Device for Gravity Sag Compensation
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Solution Overview
Problem
Long ball screws with a large slenderness ratio in linear actuators suffer from gravity sag, degrading precision and service life, and existing solutions require significant installation space and complex structures, making them impractical for small size applications.
Innovation Solution
A modular linear actuator design incorporating a support module with movable pulley blocks and a protective cover that adjusts cable tension, allowing for compact installation and effective support of the screw rod, facilitating easy adjustment and reduced component complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If support members and pulleys are used to support the screw, then gravity sag is reduced, but installation space and device complexity increase
Solution Approach 1:
The support members are integrated with the pulleys to form a unified support assembly. The pulley blocks are mounted directly on the support members, combining the support function and the belt drive function into a single compact structure, thereby reducing overall device complexity while maintaining precision support
Solution Approach 2:
The support members serve multiple functions: they provide mechanical support for the screw rod to prevent gravity sag, serve as mounting structures for the pulley blocks, and act as structural elements of the actuator housing. This multi-functionality reduces the need for separate components, simplifying the overall structure
2Manufacturing precision
If cone pulleys are used to support the screw, then gravity sag is reduced, but installation space and device complexity increase
Solution Approach 1:
The pulley blocks are nested within or mounted on the support members in a space-efficient arrangement. The compact design allows the support and drive components to occupy minimal space, making the actuator suitable for small-size applications while still providing effective gravity sag compensation
3Reliability
If multiple support components are used, then screw support is improved, but installation and adjustment complexity increase
Solution Approach 1:
The actuator is divided into modular segments: the support members with integrated pulley blocks form a self-contained support module that can be independently installed and adjusted. This segmentation allows for simplified installation procedures and easier maintenance while maintaining reliable screw support
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 modular design reduces installation space requirements, maintains precision, and extends the service life of linear actuators by providing effective support and adjustable tension, enabling their use in various sizes and applications.
Implementation Method 1
The first pulley block comprises a first frame connected to the protective cover, and a first pulley mounted in the first frame. The second pulley block comprises a second frame connected to the protective cover, and a second pulley mounted in the second frame. The cable is wound round the first pulley and the second pulley.
Implementation Method 2
The linear module comprises a base, a screw rod rotatably mounted in the base, and a transmission carriage threaded onto the screw rod and axially movable along the screw rod upon rotation of said screw rod.
Data Source
AI summary
A linear actuator includes a linear module including a base, a screw rod mounted in the base and a transmission carriage threaded onto the screw rod, and a support module including two support carriages movably mounted on the screw rod at two opposite sides relative to the transmission carriage, a protective cover disposed at one side of the base and connected to the two support carriages, two pulley blocks mounted at the two opposite ends of the protective cover and a cable wound round the pulleys of the pulley blocks and connected to the transmission carriage and the base by a respective cable connection plate. Thus, the transmission carriage utilizes the cable to carry one pulley block and then the protective cover, causing the protective cover to carry the two support carriages and the other pulley block, achieving the effect of supporting the screw rod.