Vehicle Seat Actuator Layout for Low-Noise Compact Positioning

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Solution Overview

Problem

Conventional powered seat systems in vehicles utilize brushed DC motors, which are inefficient, costly, and generate noise due to their gearing system and inconsistent operation speed.

Innovation Solution

A powered seat system utilizing an actuator assembly with a motor assembly and a gear assembly, where the motor assembly features a printed circuit board stator and the gear assembly includes a planetary gear set and cycloid gears, all concentrically arranged to minimize size and weight while improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If brushed DC motors with gearing systems are used, then the seat system can achieve positioning functionality, but the mass and packaging size increase

Engineering Contradiction:

Improvepositioning functionalityVSAvoidmass of DC motor

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

The motor assembly and gear assembly are concentrically arranged about a common axis, merging two separate assemblies into a compact integrated unit. This reduces the overall packaging volume and mass while maintaining both positioning functionality and gear reduction benefits.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The gear assembly is nested within the motor assembly, with the planetary gear set positioned inside the motor housing. This nested configuration minimizes the external dimensions and packaging space required while preserving the full functionality of both components.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Power

If brushed DC motors with gearing systems are used, then the seat system can achieve positioning functionality, but the noise output increases

Engineering Contradiction:

Improvepositioning functionalityVSAvoidnoise output

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The brushed DC motor is replaced with a brushless motor that uses electronic commutation instead of mechanical brushes. This substitution eliminates the mechanical friction and arcing that generate noise, while the planetary gear set provides the necessary mechanical advantage for positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Power

If brushed DC motors are used, then the seat system can achieve positioning functionality, but the operational efficiency decreases and costs increase

Engineering Contradiction:

Improvepositioning functionalityVSAvoidoperational efficiency

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The brushed DC motor is replaced with a brushless motor that eliminates mechanical brush contact, reducing friction losses and improving electrical efficiency. The planetary gear set provides efficient mechanical advantage with minimal energy loss, achieving both positioning functionality and improved operational efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Power

If brushed DC motors with gearing systems are used, then the seat system can achieve positioning functionality, but the packaging size increases

Engineering Contradiction:

Improvepositioning functionalityVSAvoidpackaging size

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

The motor assembly and gear assembly are concentrically arranged about a common axis, merging two separate assemblies into a compact integrated unit. This reduces the overall packaging volume while maintaining both positioning functionality and gear reduction benefits.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #7Nested doll (Nesting)

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 simplifies manufacturability, reduces noise, mass, packaging size, and costs while enhancing performance by providing consistent operation speed and improved durability.

Implementation Method 1

a planetary gear set located in the first cavity, the planetary gear set comprising a sun gear, a plurality of planet gears meshed with the sun gear and mounted on a carrier

Methodology Applied

Scientific EffectGear meshing: Gear

Implementation Method 2

a first cycloid gear mounted on the annular hub for rotation therewith, wherein the first cycloid gear may be meshed with a plurality of teeth on an inner surface of the second cavity

Methodology Applied

Scientific EffectCycloid gear meshing: Gear

Data Source

PatentUS20250050790A1Seat system

Publication Date: 2025.02.13 ADIENT US LLC

AI summary

A seat system for a vehicle may have a seat base assembly and a seat back assembly. Each of the seat base assembly and the seat back assembly may include at least one actuator assembly at least partially disposed therein. The actuator assembly may be configured to selectively adjust at least one of the seat base assembly and the seat back assembly to reach a desired angle, position, and/or height. The actuator assembly may include a motor assembly and a gear assembly, wherein the motor assembly includes a printed circuit board stator.