Integrated Motor Linear Actuator With Embedded Cooling
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Solution Overview
Problem
Existing linear actuator designs face challenges in achieving improved positioning accuracy, reduced deflection, and increased service life within a desired weight and size envelope, while also managing thermal performance in high-repetition applications like robotic welding.
Innovation Solution
The design incorporates an integrated motor actuator system with a compact stator housing, a nut assembly coupled to a thrust tube, and a cooling assembly, including active or passive cooling structures, to enhance power-to-weight ratio, thermal management, and precision control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the actuator size and weight are reduced to meet desired envelopes, then the power-to-weight ratio improves, but thermal management becomes more difficult in high-repetition applications
Solution Approach 1:
The patent embeds cooling channels directly within the actuator housing structure, nesting the thermal management system inside the mechanical components. This allows effective heat dissipation without adding external cooling apparatus that would increase weight and size, thus resolving the contradiction between compact design and thermal management.
2Speed
If the actuator components are optimized for high-speed operation, then positioning accuracy improves, but service life and endurance are reduced
Solution Approach 1:
The patent employs roller screw mechanisms that change the friction parameters between moving components, reducing wear and heat generation during high-speed operation. This parameter optimization allows the actuator to maintain high speeds while extending service life through reduced mechanical degradation.
3Manufacturing precision
If precision control components are added to improve positioning accuracy, then deflection and tool displacement are reduced, but system complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical precision systems with a streamlined roller screw mechanism combined with integrated motor control. This substitution achieves high positioning accuracy through direct-drive mechanics and electronic control rather than multiple mechanical precision components, thereby reducing overall system complexity.
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 configuration results in higher speed, accuracy, and extended service life with reduced system weight, allowing for more precise positioning and increased motor capacity, while maintaining acceptable temperatures and reducing operational costs.
Implementation Method 1
a cooling assembly, including active or passive cooling structures
Implementation Method 2
cooling assembly, including active or passive cooling structures
Data Source
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AI summary
A linear actuator system having an actuator housing, a motor assembly, a screw shaft, a thrust tube, and a nut assembly. The nut assembly is engaged with the screw shaft and directly coupled with the thrust tube. The nut assembly can define a mechanical fitting for direct physical engagement between the thrust tube and the nut assembly, absent additional load bearing components intervening therebetween. The nut assembly is configured to convert rotational motion of the rotor about the longitudinal axis to linear motion of the thrust tube along the longitudinal axis. A cooling loop can be at least partially embedded, potted or seated within the actuator housing, with a thermally conductive material disposed at least partially about the cooling loop to conduct heat from the actuator housing.