Operating Lever Overload Protection With Dual Deflection Stops
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Solution Overview
Problem
Existing operating elements in vehicles face challenges in balancing the need to withstand heavy loads while also performing sensitive controls, often leading to wear and damage due to overloading, and existing solutions like thicker materials are costly and limited in versatility.
Innovation Solution
An operating element with a pivotable operating lever and a frame guided in a housing, featuring stops and counter-stops that limit deflection angles, distributing and absorbing overload forces through a combination of materials with varying rigidity and ductility, allowing for adaptable and cost-effective protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker or heavier materials are used to sustain heavier stress, then the strength and durability of the operating element is improved, but the cost increases significantly and versatility is limited
Solution Approach 1:
The operating element is divided into components with different material properties: a rigid frame for structural strength and flexible means for limiting deflection for overload protection. This segmentation allows each part to be optimized for its specific function rather than requiring the entire element to be made of expensive heavy-duty material.
Solution Approach 2:
Different parts of the operating element have different material properties tailored to their specific functions. The frame uses rigid material for strength, while the means for limiting deflection uses flexible material for overload absorption. This local differentiation of material quality reduces overall cost while maintaining necessary strength where required.
2Reliability
If thicker or heavier materials are used to sustain heavier stress, then the strength and durability of the operating element is improved, but the cost increases significantly
Solution Approach 1:
The operating element is divided into components with different material properties: a rigid frame for structural strength and flexible means for limiting deflection for overload protection. This segmentation allows each part to be optimized for its specific function rather than requiring the entire element to be made of expensive heavy-duty material.
Solution Approach 2:
Different parts of the operating element have different material properties tailored to their specific functions. The frame uses rigid material for strength, while the means for limiting deflection uses flexible material for overload absorption. This local differentiation of material quality reduces overall cost while maintaining necessary strength where required.
3Adaptability or versatility
If a gimbal arrangement is used to allow pivotable mounting around two axes, then the versatility and range of motion of the operating lever is improved, but the susceptibility to damage from heavy loads increases
Solution Approach 1:
The means for limiting deflection act as a pre-positioned protective element that engages before critical damage can occur to the gimbal arrangement. These flexible limiters absorb overload forces and prevent them from reaching the sensitive pivot joints, cushioning the system against damage in advance.
Solution Approach 2:
The means for limiting deflection serve as an intermediary element between the operating lever and the gimbal arrangement. They mediate the transmission of forces, allowing normal operation forces to pass through while blocking or absorbing excessive overload forces that would damage the gimbal.
4Reliability
If the means for limiting deflection are made flexible to allow overload absorption, then the protection against damage is improved, but the precision and tactile feedback for sensitive controls may be reduced
Solution Approach 1:
The means for limiting deflection are designed with specific physical parameters (dimensions, material properties) that allow them to remain rigid under normal operating forces providing precise tactile feedback, while yielding under excessive overload forces. By carefully controlling parameters like thickness and material modulus, both precision and protection are achieved.
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 stable and cost-effective overload protection with minimal wear, enabling versatile operation and reduced damage by distributing and dissipating excessive forces, while allowing for interchangeable components to suit different applications.
Implementation Method 1
this restriction is a physical restriction achieved by contact between the operating lever and the means for limiting the deflection of the operating lever at a specific maximum deflection angle
Implementation Method 2
the means for limiting the deflection of the operating lever are at least partially dented by the operating lever, i.e. the operating lever is pivoted beyond the physical limitation of the means for limiting the deflection of the operating lever
Data Source
Figure 1
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Figure 3
AI summary
Operating element (1), having an operating lever (2) mounted pivotably about at least one axis, wherein the operating lever (2) has a frame (3) at a free end and is guided with this free end and the frame (3) in a housing (4), wherein the operating element (1) further has means (5) limiting the deflection of the operating lever (2) to a first deflection angle (α1), wherein the frame (3) has at least one first stop (6) and the housing (4) or means (5) for limiting the deflection of the operating lever (2) has a first counter-stop (7) corresponding to the at least one first stop (6), wherein first stops (6) and first counter-stops (7) do not contact each other at the first deflection angle (α1) of the operating lever (2), whereas they contact each other at a deflection exceeding the first deflection angle (α1) to a larger second deflection angle (α2) of the operating lever (2).