Integrated Motor Housing Flange for Engine Actuator Assembly
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Solution Overview
Problem
The existing internal combustion engine electric actuator assemblies are complex and costly to manufacture and assemble due to the use of multiple separate components, which increases the risk of interference and tolerance issues.
Innovation Solution
A one-piece fastening flange integrated with the motor housing, combined with a laterally protruding plastic end plate that provides a press fit and radial clamping action, simplifies the assembly by reducing the number of components required, ensuring a secure and defined seating of the drive motor in the housing body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate components (separate end plate, separate bracket elements) are used to fix the drive motor, then the drive motor can be securely fixed, but the manufacturing and assembly complexity increases
Solution Approach 1:
The patent integrates the fastening flange directly into the motor housing as a one-piece component, eliminating the need for separate bracket elements and fastening components. The flange is formed as an integral part of the cylindrical motor housing, reducing the total number of parts while maintaining secure fixation functionality
Solution Approach 2:
The motor housing serves multiple functions: it provides the cylindrical structural body, integrates the fastening flange for mounting, and works with the end plate to secure the drive motor in the housing body. This multi-functional design eliminates the need for separate dedicated fastening components
2Reliability
If multiple separate components are used for assembly, then secure fixation is achieved, but the assembly time and manufacturing cost increase
Solution Approach 1:
By combining the fastening flange and motor housing into a single integrated component, the assembly process is simplified. Fewer parts need to be handled, positioned, and fastened together, directly reducing assembly time and improving productivity
Solution Approach 2:
The drive motor assembly is designed as a modular unit with the integrated flange that can be assembled as one unit and then installed into the housing body. This segmentation allows for efficient pre-assembly and reduces on-site assembly complexity
3Reliability
If multiple separate components are used, then fixation is achieved, but the number of interference sources and tolerance issues increases
Solution Approach 1:
The integrated fastening flange eliminates multiple mating interfaces between separate components. By reducing the number of joints and connections, the patent minimizes the accumulation of manufacturing tolerances and reduces potential sources of interference and misalignment
Solution Approach 2:
The flange is designed with specific local features (protrusions, seating surfaces) that provide precise positioning and fixation. The local geometry of the flange and its interaction with the housing body recess creates defined tolerance zones that ensure accurate assembly
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 solution simplifies both production and assembly, enhances vibration resistance, reduces interference risks, and improves mechanical system tolerance, while minimizing the number of parts and costs.
Implementation Method 1
The end plate protrudes at least partially laterally, that is to say radially, beyond the housing and is seated with a press fit in a corresponding recess in the housing body
Implementation Method 2
at least three radial clamping ribs which project laterally beyond the cylindrical motor housing and are an interference fit in the housing body recess
Data Source
Figure 1~2
AI summary
The invention relates to an electrical adjusting arrangement (10) for internal combustion engines. The adjusting arrangement (10) has a housing body (12) holding an electric drive motor (14). The drive motor (14) has a motor housing (18) connected to a separate plastic front plate (20) on the drive side. A mounting flange (32) designed in one piece with the motor housing (18) is provided on the drive side. The front plate (20) protrudes radially past the motor housing (18), at least in places, and fits with a force fit in a corresponding recess (16, 44) of the housing body (12) and radially fixes the drive motor (14) in said manner.