Spring-Clutch Electrical Actuator for Zero-Current Holding
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Solution Overview
Problem
Existing electrical actuators for automotive applications face challenges in reducing power consumption and preventing overheating while maintaining zero holding torque when there is no drive current, and they require high current for clutch activation, which is inefficient and potentially unsafe.
Innovation Solution
An electrical actuator design featuring a first one-way spring clutch connecting a drive member and an output member, with a second spring forming a one-way clutch between the output member and a fixed tube, and a regulation cup that disengages the output member from the fixed tube, allowing for automatic return and reduced drive current usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high current is supplied to the actuator during stationary torque transfer to counteract the elasticity, then the clutch activation is ensured, but power consumption increases and the actuator may overheat
Solution Approach 1:
The patent extracts the holding function from the electrical actuator by introducing a mechanical latch mechanism. The latch takes over the stationary holding task, allowing the electrical actuator to be deactivated during stationary torque transfer, thus eliminating continuous power consumption while maintaining clutch engagement reliability
Solution Approach 2:
The patent introduces a mechanical latch as an intermediary between the electrical actuator and the clutch mechanism. This latch acts as a mediator that maintains the clutch engagement state without requiring continuous electrical power, resolving the contradiction between reliable activation and energy consumption
2Object-affected harmful factors
If a return spring is used to provide elasticity and ensure zero holding torque when drive current is zero, then safety is improved, but high current is required during activation to counteract the spring force
Solution Approach 1:
The patent applies preliminary action by using the regulation cup to manually or automatically disengage the second spring from the output member before electrical activation. This preliminary disengagement removes the opposing spring force that would otherwise require high current to overcome, reducing the power requirement during activation while maintaining the safety function
Solution Approach 2:
The patent makes the spring engagement dynamic through the regulation cup mechanism. The second spring can be engaged or disengaged from the output member based on operational requirements, allowing the system to switch between spring-assisted mode (during activation) and spring-disconnected mode (during holding), thereby optimizing power consumption while maintaining safety
3Device complexity
If the output member remains connected to the fixed tube through the second spring, then structural simplicity is maintained, but power consumption increases due to continuous electrical holding
Solution Approach 1:
The patent extracts the holding function from the electrical system and transfers it to a mechanical latch mechanism. The regulation cup and latch work together to maintain the output member position without electrical power, eliminating stationary holding power consumption while adding only minimal structural complexity
Solution Approach 2:
The patent implements self-service through the mechanical latch system that automatically maintains the clutch engagement state once activated. The latch mechanism sustains itself without external energy input, making the system self-sufficient during stationary holding and eliminating continuous power consumption
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 robust, reliable, and cost-effective actuator that reduces drive current requirements during holding positions and ensures automatic return movement when the drive current is zero, minimizing power consumption and preventing overheating.
Implementation Method 1
an output member which is rotationally connected to the drive member by means of a first one way spring clutch
Implementation Method 2
a second spring being connected to the output member and forming a one way clutch between the output member and a fixed tube forming part of a stationary housing
Implementation Method 3
a regulation cup being configured to engage with the second spring to disconnect the output member from the fixed tube
Data Source
Figure 1
Figure 2~3
AI summary
An electrical actuator (20) is provided. The actuator (20) comprises an electric drive means (22) and a drive member (26) being rotationally driven upon activation of the electric drive means (22), an output member (24) being rotationally connected to the drive member (26) by means of a first spring (28), and a second spring (32) being connected to the output member (24) and forming a one way clutch between the output member (24) and a fixed tube (34), wherein the electrical actuator (20) further comprises a regulation cup (30) being configured to engage with the second spring (32) to disconnect the output member (24) from the fixed tube (34).