Modular Worm Gear Actuator for Cost-Effective Variant Formation
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Solution Overview
Problem
Existing actuating devices require multiple variants for different applications, leading to increased costs due to the need for various components and configurations, which complicates manufacturing and reduces efficiency.
Innovation Solution
A modular actuating device with a transmission system that can be converted between single-stage, two-stage, and three-stage configurations using the same electric motor and housing, by varying the gear configurations without changing the relative position of the input and output shafts, allowing for cost-effective variant formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple variants of actuating devices are provided for different applications, then different actuating forces and speeds can be achieved, but manufacturing costs and device complexity increase
Solution Approach 1:
The housing is designed with a universal structure that can accommodate different transmission configurations (single-stage, two-stage, three-stage gear arrangements) while maintaining the same input and output shaft positions. This allows one housing design to serve multiple applications with different actuating requirements, reducing the need for multiple housing variants and lowering manufacturing costs.
Solution Approach 2:
The transmission system is segmented into modular components (different gear arrangements including single-stage, two-stage, and three-stage configurations) that can be selectively assembled within the same housing. This segmentation allows flexible configuration of gear trains to achieve different actuating forces and speeds without requiring different housing designs.
2Adaptability or versatility
If multiple variants of actuating devices are provided for different applications, then different actuating forces and speeds can be achieved, but manufacturing costs increase
Solution Approach 1:
The housing is designed with a universal structure that can accommodate different transmission configurations (single-stage, two-stage, three-stage gear arrangements) while maintaining the same input and output shaft positions. This allows one housing design to serve multiple applications with different actuating requirements, reducing the need for multiple housing variants and lowering manufacturing costs.
Solution Approach 2:
Multiple transmission configurations (single-stage, two-stage, three-stage gear arrangements) are merged into a single universal housing design. By combining these different gear arrangements within one housing structure, the patent reduces the total number of unique parts and simplifies manufacturing processes, thereby lowering production costs.
3Ease of manufacture
If the transmission is converted between different configurations, then cost-effective variant formation is enabled, but the number of components increases
Solution Approach 1:
The same set of transmission components (gears, shafts, housing) is designed to serve multiple configurations. The universal housing and reusable gear components mean that while the transmission can be configured in different ways (single-stage, two-stage, three-stage), the actual number of unique physical components does not significantly increase, as the same parts are used across different configurations.
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
Enables the production of multiple actuating devices with reduced manufacturing costs by utilizing the same components in different configurations, maintaining structural identity and minimizing the number of unique parts, thus simplifying production and increasing efficiency.
Implementation Method 1
the transmission (5) drives the drive shaft (8) to the output shaft (4) and includes a worm drive (14) for this purpose
Implementation Method 2
a first gear wheel (16, 23) that meshes with a second gear wheel (20, 24)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a control device (1) for mechanically actuating a component, comprising an electric motor (3), which has a rotor (7) having an input shaft (8), an output shaft (4) for rotationally driving a control element (10), and a transmission (5), which drivingly connects the input shaft (8) to the output shaft (4) and which has a worm (15) and a worm wheel (16), which meshes with the worm (15). The creation of variants is simplified if the worm (15) is arranged on the input shaft (8) for conjoint rotation, the worm wheel (16) and a first gear (23) are formed by a first transmission-ratio gear (21), the transmission (5) can be converted between a first configuration and a second configuration, in the first configuration, the first transmission-ratio gear (21) is arranged on the output shaft (4) for conjoint rotation such that the first gear (23) is free, in the second configuration, the first transmission-ratio gear (21) is rotatably arranged on an intermediate shaft (18), which extends parallel to the output shaft (4), such that the first gear (23) meshes with an output gear (20), which is arranged on the output shaft (4) for conjoint rotation.