Multi-Stage Gear Actuator for Compact Volume Reduction
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Solution Overview
Problem
Traditional actuators used in modern lightweight and compact devices face challenges in reducing volume due to the engagement requirements of annulus, sun, and planetary gears, which restrict the miniaturization of the actuator components.
Innovation Solution
The actuator employs multi-stage gears, comprising a worm gear shaft driving assembly, an electric motor, an annulus gear, and a plurality of multi-stage gears with helical and spur gear configurations, allowing for reduced component count and volume, while ensuring stable energy transfer and noise reduction through integrated gear components and injection molding construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional planetary gear assembly (annulus gear, sun gear, and planetary gears) is used to ensure stable transmission, then transmission reliability is improved, but actuator volume increases and cannot be reduced
Solution Approach 1:
The patent combines the sun gear and planetary gears into a single integrated multi-stage gear component. The multi-stage gear includes a first gear portion (replacing sun gear) and a second gear portion (replacing planetary gears) that are structurally merged, eliminating the need for separate sun gear and planetary gear components while maintaining stable transmission through the engagement between the second gear portion and annulus gear.
Solution Approach 2:
The multi-stage gear component performs multiple functions simultaneously: the first gear portion transmits power from the drive shaft, the second gear portion engages with the annulus gear for stable transmission, and the integrated structure provides both gear functions in a single component, reducing overall actuator volume while maintaining transmission reliability.
2Reliability
If multiple separate gear components (sun gear, planetary gears) are used to ensure proper gear engagement, then transmission stability is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple gear components into a single multi-stage gear assembly. The first gear portion and second gear portion are integrated into one component, reducing the number of separate gear parts from three (sun gear, multiple planetary gears) to one multi-stage gear, thereby simplifying the device structure while maintaining stable gear engagement through the annulus gear interaction.
3Reliability
If gear teeth path is constrained within predetermined value to ensure proper meshing, then gear engagement reliability is improved, but manufacturing flexibility decreases
Solution Approach 1:
The multi-stage gear employs different gear types at different locations: the first gear portion uses spur gear teeth for engagement with the drive shaft, while the second gear portion uses helical gear teeth for engagement with the annulus gear. This local differentiation optimizes meshing reliability at each engagement point while allowing flexible manufacturing through the integrated structure.
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 design achieves a reduced actuator volume with simplified components, stable energy transmission, and reduced noise, enabling precise and efficient operation in compact devices.
Implementation Method 1
the first outer diameter portion comprising a helical gear on an outer circumferential edge thereof; the second outer diameter portion comprising a spur gear on an outer circumferential edge thereof; the helical gears engaged with the transmission shaft correspondingly; the spur gears engaged with the inner gear correspondingly
Implementation Method 2
a worm gear shaft driving assembly comprising a worm gear shaft; an annulus gear arranged between the worm gear shaft and the transmission shaft; the moving end connected to the worm gear shaft and driving the worm gear shaft to rotate
Data Source
AI summary
An actuator with multi-stage gears includes a worm gear shaft driving assembly having a worm gear shaft, an electric motor having a transmission shaft, an annulus gear arranged between the worm gear shaft and the transmission shaft, and a plurality of multi-stage gears. The annulus gear includes an inner gear and a moving end actuated cooperatively with the inner gear on two ends thereof. The moving end is connected to and driving the worm gear shaft to rotate; each multi-stage gear is arranged between the transmission shaft and the inner gear; each multi-stage gear includes a first and a second outer diameter portions. The outer circumferential edges of the first and second outer diameter portions includes a helical gear engaged with the transmission shaft and a spur gear engaged with the inner gear respectively. Therefore, the actuator has merits of simplified components and reduced volume.