Rotary Actuator Ring Gear Integration
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Solution Overview
Problem
Conventional rotary actuators for shift-by-wire systems in vehicles require complex assembly processes due to the need for fastening members, such as screws or press-fitting, which complicates the installation of ring gears and can lead to inefficiencies and potential gear misalignment.
Innovation Solution
The rotary actuator integrates a ring gear embedded in a resin portion of the case through insert molding, eliminating the need for fastening members and reducing component count, while the ring gear's integral formation with the case prevents deformation and misalignment, enhancing assembly simplicity and gear efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fastening members (screws or press-fitting) are used to install the ring gear, then the ring gear can be securely fixed to the case, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The ring gear is integrated directly into the lower case as a single molded component, eliminating the need for separate fastening members. The resin material of the lower case inherently secures the ring gear through its structural integration, combining what were previously separate components (ring gear + case + fasteners) into one unified part.
Solution Approach 2:
The fastening members (screws or press-fitting mechanisms) are completely removed from the assembly. The patent extracts these unnecessary components by designing the ring gear to be inherently secured through its integration with the resin portion of the lower case, eliminating the need for additional fastening elements.
2Reliability
If fastening members are used to install the ring gear, then the ring gear can be fixed to the case, but the number of components increases and assembly time increases
Solution Approach 1:
The ring gear and lower case are merged into a single integrated component through molding. This eliminates the need for separate fastening members and reduces the total component count, allowing for faster assembly without compromising the reliability of the ring gear fixation.
Solution Approach 2:
The ring gear is pre-integrated into the lower case during the molding process itself. This preliminary integration ensures proper positioning and fixation before the assembly reaches the final assembly stage, eliminating the need for subsequent fastening operations and improving productivity.
3Reliability
If the ring gear is separately installed with fastening members, then the ring gear can be fixed to the case, but misalignment and deformation may occur
Solution Approach 1:
The ring gear is merged with the lower case as an integrated molded component. This integration ensures that the ring gear maintains precise alignment with the case throughout operation, as the resin material provides inherent structural support and positioning without the risk of misalignment that can occur with separately installed components.
Solution Approach 2:
The precise positioning and alignment of the ring gear are established during the molding process itself. This preliminary action ensures that the ring gear is correctly aligned with the case before the assembly is completed, preventing misalignment and deformation issues that can arise from subsequent installation steps.
Data Source
AI summary
A rotary actuator is used in a shift-by-wire system for a vehicle. The actuator includes a motor, an output shaft, a speed reducer, and a case. The motor includes a motor shaft. The output shaft is disposed in parallel with the motor shaft. The case houses the motor and the speed reducer. The case includes an upper case that houses the motor and a lower case that houses the speed reducer. The speed reducer includes a first reducer that includes a ring gear embedded in a resin portion of the lower case and a parallel-shaft type second reducer that includes a drive gear on the motor shaft and a driven gear on the output shaft. The ring gear includes an annular gear portion and a cover that protrudes radially inward from one end of the annular gear portion.