Vehicle Seat Drive Module With Integrated Overload Locking
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Solution Overview
Problem
Existing drive modules for longitudinal adjustment devices in vehicle seats lack a compact design that integrates both drive functionality and overload protection, often requiring large high-torque motors and complex spindle systems.
Innovation Solution
A compact drive module with a rack drive mechanism and an integrated overload element, such as a locking worm, which allows for simultaneous longitudinal adjustment and overload protection using a single drive motor and a multi-shaft design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional drive module with single shaft design is used, then the structure is simple, but it cannot provide both drive function and overload protection simultaneously
Solution Approach 1:
The drive shaft is divided into multiple shaft portions (first shaft portion, second shaft portion) that are independently functional. The first shaft portion connects to the drive gear for longitudinal adjustment, while the second shaft portion connects to the overload element for crash protection. This segmentation allows each shaft portion to perform its specific function independently, achieving multi-functionality without excessive complexity.
Solution Approach 2:
The drive module is designed as a universal component that integrates both drive functionality and overload protection in a single unit. The housing (gear unit housing) accommodates both the drive gear and overload element, and the multi-shaft design enables the single drive module to perform multiple functions: normal longitudinal adjustment and crash overload protection, eliminating the need for separate drive and protection mechanisms.
2Power
If large high-torque drive motors are used to ensure sufficient driving force, then the drive capability is improved, but the size and cost of the drive module increases
Solution Approach 1:
The patent replaces the traditional mechanical transmission system (trapezoidal spindle) with a rack drive mechanism. The rack and pinion arrangement provides mechanical advantage through gear engagement, allowing a smaller motor to generate sufficient driving force for the seat longitudinal adjustment. The gear unit acts as a mechanical multiplier, converting the motor's rotational motion into linear motion of the rail assembly with amplified force.
Solution Approach 2:
The drive module incorporates a gear unit with specific gear ratio to transform the motor's output parameters. The gear reduction increases the torque delivered to the rack while reducing the rotational speed, optimizing the motor's performance characteristics for this application. This parameter transformation allows a compact motor to produce the high linear force needed for seat adjustment.
3Reliability
If separate drive and overload protection systems are used, then each function is optimized, but the overall device complexity and space requirement increases
Solution Approach 1:
The drive gear and overload element are merged into a single integrated assembly housed within the same housing. Both components share the same mounting structure and spatial arrangement, with the drive gear positioned to engage the rack and the overload element positioned to engage the rail assembly in the event of overload. This merging reduces the number of separate systems while maintaining the reliability of overload protection through coordinated design.
Solution Approach 2:
The gear unit serves as an intermediary mechanism between the motor and the rail assembly. It transmits and transforms the motor's rotational motion into linear motion while also providing a mechanical interface for the overload element. The gear teeth act as an intermediary that can either transmit normal operating forces or, when overloaded, allow the overload element to engage and provide crash protection, mediating between the drive system and the protected component.
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 enables a compact and efficient drive module that combines the functionality of a rack drive for longitudinal adjustment with an overload protection mechanism, allowing for reliable operation even in accident scenarios, while utilizing smaller and more cost-effective drive motors.
Implementation Method 1
a drive unit having at least a single drive motor which comprises a drive shaft
Implementation Method 2
at least one gear unit and at least one overload element which for movement is coupled to a second shaft portion of the drive shaft. The gear unit couples the first shaft portion to the drive gear
Implementation Method 3
the overload element can be designed as a locking mechanism. In this way, the drive module combines a drive unit which has a single drive motor and is designed as a rack drive with an overload element which is designed as a locking mechanism
Data Source
AI summary
A drive module may have a drive unit having a single drive motor which may have a drive shaft having a plurality of shaft portions, having at least one drive gear which for movement is coupled to a first shaft portion. The drive module may also have at least one gear unit and at least one overload element. The as least one overload element is coupled to a second shaft portion. The gear unit couples the first shaft portion to the drive gear, and the second shaft portion to the overload element.