Stacked Gear Actuator Layout Using a Bend Shaft
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Solution Overview
Problem
Conventional gear configurations in actuators require more space than ideal due to straight shafts, limiting the positioning of gears and increasing the overall size of the actuator.
Innovation Solution
The use of a bend shaft with a lower portion, crosspiece, and upper portion allows gears to be mounted in a way that their central axes can intersect, enabling a more compact gear configuration by positioning gears closer together and reducing the overall space required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If straight shafts are used to mount gears, then the gear configuration is simple and easy to manufacture, but the actuator consumes more space and requires a larger overall size
Solution Approach 1:
The patent applies curvature by replacing straight shafts with bent shafts that have curved configurations. The bent shafts allow gear central axes to intersect and enable gears to be positioned closer together in three-dimensional space, reducing the overall actuator volume while maintaining manufacturing feasibility through standard bending processes
2Volume of stationary object
If gears are positioned closer together to reduce space, then the actuator size is reduced, but the gear configuration becomes more complex and difficult to manufacture
Solution Approach 1:
The patent transitions from a two-dimensional gear arrangement (with straight shafts) to a three-dimensional configuration using bent shafts. This dimensional change allows gears to be stacked and positioned in multiple levels, enabling compact space utilization while maintaining relatively simple manufacturing processes for each individual component
3Ease of manufacture
If conventional gear configurations are used, then the manufacturing process is straightforward, but additional components cannot be included and versatility is limited
Solution Approach 1:
The bent shaft configuration creates a multi-functional platform that can accommodate not only gears but also additional components such as sensors, magnets, and other actuation elements. This universal mounting structure enhances actuator versatility while maintaining manufacturing simplicity through standardized bent shaft designs
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
AI summary
A gear train (250) is contained within the housing (202) of an actuator (102, 200), is coupled to a movable component outside the housing (202), and includes a first gear (302, 303, 304, 305, 306, 440, 442) and a second gear (302, 303, 304, 305, 306, 440, 442). A bend shaft (400) is fixed to an internal surface (150, 156, 158) of the housing (202) and supports the first and second gears (262, 272, 282, 292, 302, 303, 440). The bend shaft (400) includes a lower portion (402), a crosspiece (404), and an upper portion (406). The lower portion (402) has a first end (410, 412) coupled to the housing (202) and a second end (410, 412) offset from the first end (410, 412), and extends from the first end (410, 412) to the second end (410, 412) along a first direction. The crosspiece (404) is oriented orthogonal to the first direction and extends from the second end (410, 412) of the lower portion (402). The upper portion (406) has a third end (410, 412) coupled to the crosspiece (404) and a fourth end (410, 412) offset from the third end (410, 412), and extends from the third end (410, 412) to the fourth end (410, 412) along the first direction.