Lock Clutch With Selective Shaft Coupling for Reliable Door Locks
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Solution Overview
Problem
Existing door locks face challenges in achieving reliable operation with low manufacturing costs and low power requirements for changing the clutch state.
Innovation Solution
A door lock clutch design comprising a first and second shaft with a movably supported coupling element that transitions between closed and open positions, providing torque-proof coupling in the closed position and allowing relative rotation in the open position, utilizing a minimal number of parts and innovative shaft configurations to enhance reliability and reduce manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional door lock mechanism is used, then reliable operation is achieved, but manufacturing costs and device complexity increase
Solution Approach 1:
The door lock mechanism is divided into two independent shafts (first shaft and second shaft) that can rotate relative to each other. The coupling element selectively couples these shafts, creating modular segments that can be manufactured separately and assembled, reducing overall manufacturing complexity and costs while maintaining reliability through the selective coupling mechanism.
Solution Approach 2:
The coupling element is designed to be movable between a first position (coupling the shafts) and a second position (releasing the coupling). This dynamic capability allows the lock to transition between locked and unlocked states, providing reliable operation while using a minimal number of parts that can be actuated by simple mechanisms.
2Reliability
If a traditional door lock mechanism is used, then reliable operation is achieved, but power requirements for changing clutch state increase
Solution Approach 1:
The coupling element is biased by a spring into the first position (coupled state). To unlock, the coupling element must be actively moved to the second position against the spring bias, but once released, the spring automatically returns it to the coupled position. This self-service mechanism reduces the power required for actuation, as the spring provides the return force without requiring additional energy input.
3Device complexity
If a minimal number of parts is used, then manufacturing costs are reduced, but reliability may worsen
Solution Approach 1:
The coupling element serves multiple functions: it couples the first and second shafts together, transmits torque between them, and can be selectively disengaged to release the coupling. This multi-functionality allows the door lock to achieve reliable operation with a minimal number of parts, as the coupling element replaces what would traditionally require multiple separate components.
Solution Approach 2:
The coupling element is received within a recess of the second shaft, creating a nested configuration. The first shaft extends into the recess of the second shaft, and the coupling element fits within this nested structure. This nesting arrangement consolidates multiple components into a compact configuration, reducing the number of separate parts while maintaining the reliability of the coupling mechanism.
Data Source
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AI summary
A lock clutch comprising a first shaft 100, a rotational axis 2), a second shaft 200 and a movably supported coupling element 300, wherein the coupling element establishes and/or provides for a positive locking between the first shaft 100 and the second shaft 200 if the coupling element is shifted from an open position into a closed position is particularly reliable and cost effective, if a first end section of the first shafts extends into a recess in a second end section of the second shaft, wherein the recess is delimited by a rotationally variant delimiting surface and if the first end section has a first peripheral surface section and a second peripheral surface section 120, wherein the first peripheral surface section is rotationally variant under a rotation around the first rotational axis. A first gap 231 is formed between the first peripheral surface section 110 and the delimiting surface 210. Axially adjacent to the first peripheral surface section 110 is the second peripheral surface section 120 with a maximum radial distance r2,max (φ, l) from the rotational axis being smaller than the minimum distance dmin(l) between the coupling element 300 in its open position and the axis 2. Further, in the closed position, the coupling element 300 extends into the first gap 231 and thereby provides for the positive locking between the first shaft 100 and the second shaft 200. In the open position, the coupling element 300 is axially aligned with the second peripheral surface section 120.