Three-Stage Transmission for High Torque Actuation
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Solution Overview
Problem
Existing control devices for mechanically actuating components, such as flaps and valves, face challenges in achieving high actuating torque while maintaining a compact design, as they require increased drive torque from the electric motor, which is inefficient and costly.
Innovation Solution
The integration of a three-stage transmission using a worm drive and additional gear wheels on the output shaft allows for a high transmission ratio, enabling high torque output at low rotational speed without increasing motor torque, and utilizes existing space efficiently for a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a conventional single-stage transmission is used, then the device structure is simple, but the transmission ratio is insufficient to achieve high actuating torque without increasing motor torque
Solution Approach 1:
The transmission is divided into three independent stages: a worm drive stage (first gear stage) and two planetary gear stages (second and third gear stages). Each stage provides a specific transmission ratio, and their combined effect achieves a very high overall transmission ratio (up to 1:100 or more), enabling high actuating torque without increasing motor torque requirements.
Solution Approach 2:
The planetary gear stages are nested within the worm drive structure. The planetary gear sets are positioned inside the housing formed by the worm drive components, allowing multiple transmission stages to occupy the same spatial envelope. This nested arrangement achieves high transmission ratio while maintaining a compact device footprint.
2Force
If the electric motor is designed for increased drive torque to achieve high actuating torque, then the actuating torque requirement is met, but the motor size and device volume increase
Solution Approach 1:
The transmission ratio is changed from a single-stage to a multi-stage configuration, fundamentally altering the torque multiplication mechanism. This parameter change allows the motor to operate at lower torque and higher speed, while the multi-stage transmission provides the necessary torque multiplication, thereby reducing motor size.
3Force
If additional transmission stages are added to increase transmission ratio, then the actuating torque is improved, but the device volume increases
Solution Approach 1:
The planetary gear stages are nested within the housing formed by the worm drive components. The planetary gear sets are positioned inside the space created by the worm and housing structure, allowing multiple transmission stages to occupy the same spatial envelope rather than adding linearly to the device volume.
Solution Approach 2:
The transmission stages are arranged in a three-dimensional configuration rather than a linear sequence. The planetary gear sets utilize the radial and axial space within the worm drive housing, effectively using three-dimensional space to accommodate multiple transmission stages without increasing the device footprint in any single dimension.
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 configuration provides a compact and efficient control device capable of delivering high actuating torque with reduced motor requirements, enhancing the mechanical actuation capabilities while minimizing space and production costs.
Implementation Method 1
a worm drive with worm (16) and worm wheel (17)
Implementation Method 2
the driveshaft (8) carries a first gear wheel (18) which meshes with a second gear wheel (19)
Data Source
AI summary
A control device may include an electric motor having a stator and a rotor with a driveshaft, an output shaft, a transmission having a worm drive with a worm and a worm wheel, and a drive axis of the drive shaft extending inclined to an output axis of the output shaft. The worm may be arranged non-rotatably and may mesh with the worm wheel, which may be rotatably arranged on the output shaft and non-rotatably connected to a first gear wheel, which may be rotatably arranged on the output shaft and may mesh with a second gear wheel, which may be rotatable about an intermediate axis extending parallel to the output axis and may be non-rotatably connected to a third gear wheel, which may be rotatable about the intermediate axis and may mesh with a fourth gear wheel, which may be non-rotatably arranged on the output shaft.