Motor-Cam Plunger Lock for Compact Vehicle Shifter Control
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Solution Overview
Problem
Conventional solenoid locking mechanisms are large, costly, and limited in response time and load capacity, requiring additional mechanisms to manage temperature and voltage variations, and they cannot position multiple pistons effectively.
Innovation Solution
A plunger lock mechanism using an electric motor to rotate a cam, which actuates spring-loaded plungers between engaged and disengaged positions with a shift lever, allowing for rotation and incorporating a worm shaft and bevel gear system, along with proximity sensors for position detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solenoid locking mechanism is used, then the locking function is provided, but the size and cost increase
Solution Approach 1:
The patent combines the locking and unlocking functions into a single plunger mechanism actuated by a motor-cam assembly. The plunger serves dual purposes: blocking rotation when engaged and permitting rotation when retracted. This merging of functions eliminates the need for separate solenoid and locking mechanism components, reducing overall size while maintaining reliability.
Solution Approach 2:
The motor-driven cam mechanism serves multiple functions: it actuates the plunger for locking/unlocking, provides positional control through the cam profile, and enables precise timing through the worm gear reduction. This multi-functional design replaces the single-function solenoid, reducing component count and size while improving performance.
2Reliability
If a solenoid locking mechanism is used, then the locking function is provided, but the cost increases
Solution Approach 1:
The patent employs a motor-cam-plunger assembly that uses inexpensive, easily manufactured components. The cam can be produced as a simple machined part or even a molded component, and the plunger is a basic cylindrical element. These replace expensive solenoids with cheaper alternatives that achieve the same functional result through mechanical leverage and precise timing.
Solution Approach 2:
The patent replaces the electromagnetic solenoid system with a motor-driven mechanical cam system. This substitution eliminates the need for expensive electromagnetic components, complex wiring, and thermal management systems, while providing comparable or superior performance through purely mechanical means that are easier and cheaper to manufacture.
3Reliability
If a solenoid locking mechanism is used, then the locking function is provided, but the response time is limited
Solution Approach 1:
The motor-cam system is pre-positioned and ready to actuate the plunger at any time. The cam profile is designed to provide immediate mechanical advantage when the motor activates, causing the plunger to engage or disengage rapidly. This preliminary positioning and mechanical leverage enable faster response times compared to solenoids that must build electromagnetic force from scratch.
Solution Approach 2:
The patent uses a dynamic cam mechanism that can rapidly change the position of the plunger through rotational motion. The cam profile is optimized to provide high-speed actuation during critical phases of engagement and disengagement, enabling the system to respond faster to control signals than solenoid-based systems with their inherent electromagnetic response delays.
4Reliability
If a solenoid locking mechanism is used, then the locking function is provided, but the load capacity is limited
Solution Approach 1:
The patent employs a spring-loaded plunger mechanism where the spring provides continuous force to maintain engagement. This spring force acts as a counterbalance to external loads attempting to disengage the lock, enabling the system to handle higher loads than a solenoid could provide alone. The motor only needs to overcome the spring force during actuation, not the full load, greatly increasing load capacity.
Solution Approach 2:
The cam mechanism uses curved surfaces to amplify the motor's rotational force into high linear force on the plunger. The cam profile is designed to provide mechanical advantage at critical points in the actuation cycle, enabling the small motor to generate sufficient force to move the heavy plunger against spring pressure and external loads, thereby increasing overall load capacity.
5Reliability
If a solenoid locking mechanism is used, then the locking function is provided, but additional mechanisms are required for temperature and voltage management
Solution Approach 1:
The patent replaces the electromagnetic solenoid system with a motor-driven mechanical cam system. This substitution eliminates the need for expensive electromagnetic components, complex wiring, and thermal management systems, while providing comparable or superior performance through purely mechanical means that are easier and cheaper to manufacture.
Solution Approach 2:
The mechanical cam-plunger system is inherently more tolerant of environmental variations. The mechanical components do not require active thermal management or voltage regulation like electromagnetic solenoids. The system serves itself through pure mechanical advantage and spring-loaded engagement, eliminating the need for additional temperature and voltage management mechanisms.
6Reliability
If a conventional locking mechanism is used, then the locking function is provided, but the ability to position multiple pistons is lost
Solution Approach 1:
The motor-driven cam mechanism serves multiple functions: it actuates the plunger for locking/unlocking, provides positional control through the cam profile, and enables precise timing through the worm gear reduction. This multi-functional design replaces the single-function solenoid, reducing component count and size while improving performance.
Solution Approach 2:
The patent uses a dynamic cam mechanism that can rapidly change the position of the plunger through rotational motion. The cam profile is optimized to provide high-speed actuation during critical phases of engagement and disengagement, enabling the system to respond faster to control signals than solenoid-based systems with their inherent electromagnetic response delays.
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 a compact, cost-effective locking mechanism capable of positioning multiple plungers, improving response time and load handling across various temperature and voltage ranges, enabling efficient operation of vehicle shifter assemblies.
Implementation Method 1
The at least one plunger is spring biased into an engaged position with the shift lever or other independently rotatable component
Implementation Method 2
Actuated rotation of the cam in turn counter-biases one or more plungers or lock arms in a retracting or disengaging direction from an engaged location with the shift lever or other independently rotatable component in order to unlock the component
Implementation Method 3
The electric motor further includes a worm shaft actuating a worm gear
Implementation Method 4
the cam including an extending end in slaved relationship with the bevel gear so that actuation of the motor causes rotation of the cam
Implementation Method 5
A magnet is supported upon an end of the cam and, in response to rotation relative to a proximity located sensor, detects a position of the cam
Data Source
AI summary
A plunger lock mechanism including a housing containing a rotationally supported lever shaped component, the component including at least one notch or recess configured within an arcuate surface. An electric motor is configured to rotate a cam extending within the housing, the cam actuating at least one plunger having an extending portion aligning with a selected notch. Upon rotation of the cam by the motor, the plunger is caused to displace between either of engaged and disengaged positions with the component such that, when disengaged, permitting rotation of the component.