Integral Operating Lever with Weak Interface for Torque Limiting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing operating lever with a torque limiter has a complex structure and a gap between the lever body and grip, leading to deformation during normal operation, causing discomfort and failure to prevent excessive load application to the power transmitter.
Innovation Solution
An operating lever with a fixing portion, handle, and interface that are integrally formed, featuring a weak portion at the interface other than the outer periphery, which is weaker than other parts, and includes a rib with densely formed cylindrical holes to enhance strength and rigidity, preventing excessive load transmission to the power transmitter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque limiter is provided on the operating lever to prevent excessive load application to the power transmitter, then the power transmitter is protected from excessive force, but the structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The torque limiter function is merged into the operating lever itself by forming a weak portion directly in the lever body at the interface between the fixing portion and handle. This integration eliminates the need for separate torque limiter components while maintaining the protective function against excessive force applied to the power transmitter.
Solution Approach 2:
A weak portion is created at a specific location (the interface between fixing portion and handle) of the operating lever. This localized weakness allows the lever to deform preferentially at this point when excessive force is applied, providing torque limiting protection without compromising the overall structural integrity or adding complexity to the entire device.
2Ease of manufacture
If the operating lever is made with separate components (lever body and grip) connected by hinges, then assembly is facilitated, but gaps are formed that cause deformation during normal operation leading to uncomfortable sensation
Solution Approach 1:
The operating lever is formed as a single integral piece comprising the fixing portion, interface, and handle without separate components or hinges. This integration eliminates gaps between components, preventing unwanted deformation during normal operation and providing a comfortable sensation to the user while maintaining ease of manufacture through integral forming processes.
3Power
If the operating lever has a long length to provide adequate leverage, then mechanical advantage is improved, but the lever vibrates in the right-left direction around the rear end causing instability
Solution Approach 1:
Projections are added to the operating lever that extend in a direction perpendicular to the lever's main longitudinal axis. These projections interact with corresponding recesses in the cover to provide lateral support and constraint, stabilizing the lever's posture in the right-left direction while preserving its length and mechanical advantage for vertical movement.
Solution Approach 2:
The projections on the operating lever act as intermediaries that engage with recesses in the cover structure. This engagement provides lateral support and constraint, preventing unwanted vibration and instability while allowing the lever to maintain its full length for adequate mechanical advantage during vertical operation.
4Ease of operation
If the operating lever moves vertically along the cover, then the power transmitter is actuated, but friction and resistance are generated between the lever and cover
Solution Approach 1:
The friction-generating contact surface between the operating lever and cover is eliminated by extracting the sliding function. Instead of sliding along the cover, the lever is positioned to engage with specific projections and recesses that guide movement and minimize contact area, thereby reducing friction and resistance during vertical movement while maintaining operational smoothness.
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 a simpler structure, prevents uncomfortable sensations, and effectively suppresses the transmission of large forces to the power transmitter, ensuring stable operation and reduced friction with the cover, enhancing the overall usability and reliability of the operating lever.
Implementation Method 1
the interface has a weak portion at a portion other than the outer periphery of the interface, the weak portion being weaker than other portions
Implementation Method 2
includes a rib with densely formed cylindrical holes to enhance strength and rigidity
Data Source
AI summary
An operating lever includes a fixing portion, a handle, and an interface. The fixing portion is to be fixed to a power transmitter. The handle is to be gripped by a user. The interface connects the fixing portion and the handle. The fixing portion, the handle, and the interface are integrally formed. The interface has a weak portion at a portion other than the outer periphery of the interface, the weak portion being weaker than other portions.