Integrated Overload Protector in Spur Gear Transmission
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Solution Overview
Problem
Existing adjustment drives for vehicle components, such as tailgates and doors, face challenges in compact design and cost-effectiveness while providing overload protection, often leading to damage during simultaneous manual and automatic operation due to the need for additional space and complex installations.
Innovation Solution
Integration of overload protection into the transmission component of the drive unit, specifically within the spur gear, allows for a compact design without additional installation space, using a spur gear with an inner ring and outer ring coupled by a spring, enabling efficient torque transmission and reduced risk of damage from excessive forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overload protection is arranged separately on the adjustment drive or component, then overload protection function is provided, but installation space increases and device complexity increases
Solution Approach 1:
The overload protection function is merged with the spur gear transmission component. The spur gear includes an inner ring and outer ring with a spring coupling mechanism integrated directly into the gear structure, eliminating the need for separate overload protection devices and reducing installation space.
Solution Approach 2:
The spur gear is designed to serve multiple functions: power transmission and overload protection. The spring-coupled inner and outer rings of the spur gear enable it to transmit torque while automatically providing overload protection when excessive forces are applied, making the component universal in function.
2Reliability
If overload protection is arranged separately on the adjustment drive or component, then overload protection function is provided, but manufacturing cost increases due to additional components and assembly steps
Solution Approach 1:
The overload protection mechanism is combined with the spur gear manufacturing process. The inner ring, outer ring, and spring coupling are integrated into a single manufacturable unit, reducing the number of parts to be produced and assembled, thereby lowering manufacturing costs.
Solution Approach 2:
The spur gear is designed as a multi-functional component that simultaneously provides power transmission and overload protection. This eliminates the need for separate overload protection parts, reducing total component count and assembly complexity, which directly reduces manufacturing cost.
3Power
If high gear reduction is used to transmit high torque, then torque transmission capability is improved, but device complexity and installation space increase
Solution Approach 1:
The overload protection mechanism is merged with the existing gear reduction structure. The spring-coupled inner and outer rings are integrated into the spur gear of the reduction mechanism, allowing the same component to provide both high torque transmission and overload protection without adding separate mechanisms.
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
This solution enables a smaller, more cost-effective adjustment drive that can withstand excessive forces, reducing the risk of damage and simplifying installation, while maintaining high torque transmission efficiency and compactness.
Implementation Method 1
a spring (603'), which couples the inner ring (601') and the outer ring (602')
Implementation Method 2
a spring (603'), which couples the inner ring (601') and the outer ring (602') in a manner that the spring (603') can be elastically deformed in a rotation direction of the first output shaft (24)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An adjustment drive for a component which can be operated both by means of the adjustment drive and also manually, in particular of a motor vehicle, wherein the adjustment drive comprises a drive unit and an output unit, wherein the output unit is provided in order to reduce the output speed of the drive unit, wherein the drive unit comprises a transmission component into which an overload protector is integrated.