Shared BLDC Seat Actuator Assembly With Function-Specific Reducers

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Solution Overview

Problem

Conventional power seat actuators require multiple motors for different functions, leading to increased manufacturing costs and complexity due to the need for various production facilities, and there is a trend towards using BLDC motors which demand additional sensing, switching, and protection components, while also needing to be compact.

Innovation Solution

An actuator group for automotive power seats that shares a BLDC motor assembly across various actuators, utilizing a reducer assembly with different configurations for each actuator type to achieve shared motor use, reduced manufacturing costs, and a more compact form factor, including a PCB with a sensor for rotor position detection and a gear set with a worm and worm wheel for deceleration, with a bearing guide to reduce vibration and noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple different motors are used for different actuator functions in power seats, then each actuator can be optimized for its specific function, but manufacturing cost increases and production facilities become more complex

Engineering Contradiction:

Improveactuator function optimizationVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The patent applies universality by designing a single motor assembly that can serve multiple actuator functions in power seats. The motor assembly is configured to work with different reducer assemblies to achieve various actuator functions (recliner, relax, legrest, tilt, slide, height adjustment), eliminating the need for separate motors for each function and thereby reducing manufacturing cost and facility complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a BLDC motor is applied to power seat actuators, then noise is reduced and longevity is improved, but additional components for sensing, switching, and protection must be mounted

Engineering Contradiction:

Improvemotor longevityVSAvoidcomponent quantity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the sensor, controller, and motor into a single integrated motor assembly. The sensor for detecting rotor position is mounted on the motor assembly, and the controller is integrated within the same assembly, eliminating the need for separate mounting of these components and reducing overall device complexity while maintaining the reliability benefits of BLDC motors

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple different motors are used for different actuator functions, then each actuator can be optimized for its specific function, but the overall system size and weight increase

Engineering Contradiction:

Improveactuator function optimizationVSAvoidactuator group weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 actuator group reduces manufacturing costs and achieves a more compact design by sharing the motor assembly across different actuators, while maintaining performance and reducing noise and vibration through the use of a softer bearing guide and optimized gear configurations.

Implementation Method 1

a sensor 11b for detecting a position of a rotor of the BLDC motor

Methodology Applied

Scientific EffectPosition detection:

Implementation Method 2

a gear set with a worm and worm wheel for deceleration

Methodology Applied

Scientific EffectWorm drive: Worm Drive

Implementation Method 3

with a bearing guide to reduce vibration and noise

Methodology Applied

Scientific EffectVibration damping: Damping

Data Source

PatentUS20230373354A1Actuator for automotive power seat sharing BLDC motor

Publication Date: 2023.11.23 DAS CO LTD

AI summary

An actuator group for an automotive power seat according to the present disclosure includes: three or more types of actuators constituting the automotive power seat, and each actuator of the actuator group includes: a motor assembly 10 having a BLDC motor configured therein; and a reducer assembly 20 coupled to the motor assembly 10 on a side where a motor shaft 15 of the BLDC motor extends and receiving a rotational force of the BLDC motor to decelerate, and the reducer assembly 20 is configured differently from each other depending on a type of an actuator, but the motor assembly 10 is shared.