Motorized Lock Gearbox Clutch for Bidirectional Torque
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Solution Overview
Problem
Conventional door locks with integrated clutches allow powered rotation in only a single rotational direction, limiting the utility of electromechanical actuators, and existing clutches do not accommodate the varying rotation requirements of door locks in different regions, such as the need for 180 degrees of rotation in European locks.
Innovation Solution
A clutch mechanism for door locks that decouples the actuator from the output shaft using translational movement based on manual or actuator torque input, allowing for bidirectional operation and accommodating multiple rotations, while ensuring smooth manual operation and efficient torque transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a conventional clutch is used to allow manual operation, then the actuator can be decoupled during manual use, but the clutch only allows powered rotation in a single rotational direction, limiting the utility of electromechanical actuators
Solution Approach 1:
The clutch mechanism dynamically adapts its engagement state based on the direction of rotation. During manual operation in the first rotational direction, the clutch disengages to allow smooth manual turning. During powered operation in the second rotational direction, the clutch engages to transmit torque from the actuator. This dynamic behavior resolves the contradiction by making the clutch's engagement state dependent on the operational mode and rotation direction.
Solution Approach 2:
The clutch mechanism is segmented into multiple functional components including a first clutch component with first engagement surfaces for manual operation, and a second clutch component with second engagement surfaces for powered operation. This segmentation allows independent optimization of each component for its specific function, enabling both smooth manual operation and effective powered bidirectional rotation.
2Adaptability or versatility
If a clutch mechanism is added to enable bidirectional operation and multiple rotations, then adaptability improves, but the device complexity increases
Solution Approach 1:
The clutch mechanism merges the functions of manual operation and powered operation into a single integrated assembly. The first and second clutch components are combined in a compact arrangement where both can operate within the same space. The engagement surfaces are positioned such that manual rotation in one direction disengages the first clutch while powered rotation in the opposite direction engages the second clutch, eliminating the need for separate mechanisms.
Solution Approach 2:
The clutch mechanism is designed as a universal component that handles multiple functions: it accommodates manual operation in one rotational direction, powered operation in the opposite rotational direction, and allows multiple rotations to accumulate. This multi-functionality is achieved through the symmetrical arrangement of engagement surfaces that can interact with either the manual input or the actuator output depending on the direction of applied torque.
3Power
If the clutch engages during manual operation, then torque transmission is efficient, but manual operation becomes difficult due to actuator interference
Solution Approach 1:
The mechanism extracts the actuator from the torque transmission path during manual operation by disengaging the first clutch component. The first engagement surfaces are positioned and oriented such that when manual torque is applied in the first rotational direction, the clutch components separate, completely removing the actuator's interference. During powered operation in the second direction, the actuator re-engages with the second clutch component to transmit torque efficiently to the output shaft.
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 reliable, bidirectional operation of door locks with electromechanical actuators, ensuring smooth manual operation and efficient torque transmission without interference from the actuator, suitable for locks requiring multiple rotations.
Implementation Method 1
The inclined projection of the thumb turn shaft is configured to move the coupler from the disengaged position to the engaged position when the thumb turn shaft rotates relative to the coupler
Implementation Method 2
The inclined wedge of the input gear is configured to engage the clutch disk to move the clutch disk from the disengaged position to the engaged position when the input gear rotates relative to the clutch disk
Data Source
AI summary
A clutch for a door lock may comprise an output shaft configured to operate the door lock, and a thumb turn shaft coupled to the output shaft comprising an inclined projection. The clutch may also comprise an input gear configured to be coupled to an actuator output, and a coupler coupled to the input gear such that the coupler and input gear rotate together. The coupler may be configured to translate between an engaged position and a disengaged position, where the inclined projection of the thumb turn shaft is configured to move the coupler from the disengaged position to the engaged position when the thumb turn shaft rotates relative to the coupler. In the disengaged position the coupler may be decoupled from the output shaft.