Stop Module Toggle Lever Drive Reduces Actuation Force
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stop modules for automated machining and conveyor systems require high forces for the up-and-down motion of stop elements, leading to large and costly electrical rotary drives.
Innovation Solution
A stop module utilizing a toggle lever device cooperating with an electrical rotary drive, which converts rotary motion into linear motion using a connecting rod assembly, allowing the stop element to move between positions with minimal force expenditure, and incorporating a damping device to reduce forces on objects during contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional electrical rotary drive is used to move the stop element, then the stop element can be actuated, but high forces are required and the drive becomes large and costly
Solution Approach 1:
A toggle lever device is introduced as an intermediary mechanism between the electrical rotary drive and the stop element. This lever device converts the rotary motion into linear motion with mechanical advantage, significantly reducing the force required from the electrical drive while maintaining effective actuation of the stop element.
Solution Approach 2:
The patent replaces a direct mechanical drive system with a combination of electrical rotary drive and toggle lever mechanism. The electrical drive provides only the necessary rotational force, while the mechanical lever system amplifies this force to achieve the high stopping forces needed, thereby reducing the power requirements of the electrical component.
2Reliability
If the stop element is positioned in the movement plane to stop objects, then objects can be stopped for machining, but great forces are exerted by objects on the stop element
Solution Approach 1:
The stop element is designed to be dynamically positionable between two states: protruding into the movement plane to stop objects for machining operations, and retracted to allow continuous conveyance. This dynamic positioning capability allows the system to adapt between stopping and moving states as required by the machining process.
Solution Approach 2:
The toggle lever device acts as a mediator that handles the force interaction between objects and the stop element. It provides mechanical advantage to counterbalance the great forces exerted by objects during stopping, while maintaining reliable contact for machining operations.
3Productivity
If the stop element is moved out of the movement plane to enable conveyance, then objects can move freely, but the stop element must be precisely positioned back for stopping
Solution Approach 1:
The electrical rotary drive with toggle lever mechanism provides precise control over the stop element's position. The rotary motion can be precisely controlled to position the stop element accurately in the movement plane when needed, while allowing free conveyance when retracted, thus maintaining both productivity and positioning precision.
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 efficient and cost-effective movement of stop elements with reduced force requirements, allowing for gentle handling of objects and maintaining their position during machining operations.
Implementation Method 1
the forces required for the up-and-down motion of the stop member in a stop module embodied in this way are quite high, so that the electrical rotary drive must be correspondingly large and thus entails relatively high costs
Implementation Method 2
incorporating a damping device to reduce forces on objects during contact
Data Source
AI summary
In a stop module, in particular for automated machining and conveyor systems, a stop element for objects moving in a direction of motion in a movement plane is located on a base body, and the stop element is movable by an electrical rotary drive between a first terminal position, in which the stop element protrudes into the movement plane of the objects, and a second terminal position, in which the stop element enables a motion of objects in the movement plane. The motion of the stop element in and out of the movement plane of objects is implemented by a toggle lever device cooperating with the electrical rotary drive, which toggle lever device has at least two lever elements, connected to one another via a first pivot point, and the electrical rotary drive cooperates with the first pivot point.