Universal Lift Actuator Design for Load Range Standardization
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Solution Overview
Problem
Existing electric lift actuators face challenges in cost reduction, performance enhancement, and reliability improvement, particularly in achieving standardized designs across various load ranges and applications, which complicates manufacturing, serviceability, and scalability.
Innovation Solution
The design incorporates a controller-driven electrical motor with a wire rope drum, load sensors, slack sensors, universal motor and reducer assemblies, and advanced operator interfaces, including a handle with 360-degree rotation and optical proximity sensors, to enhance load handling capacity, reliability, and user feedback, while reducing component variability and facilitating remote diagnostics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric lift actuators are designed with customized components for different load ranges, then performance and reliability for specific applications are improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent implements a universal actuator design where a single motor-reducer assembly can accommodate multiple load ranges (e.g., 50lb, 100lb, 200lb capacities) by changing only the drum and cable guide components. This multi-functionality approach maintains high reliability across applications while reducing device complexity through standardization of core components.
Solution Approach 2:
The actuator is divided into modular segments: a universal motor-reducer assembly that remains constant, and interchangeable drum-cable guide modules that are selected based on specific load requirements. This segmentation allows the system to maintain reliability through standardized core components while adapting to different applications through simple module swaps.
2Productivity
If multiple customized components are used across different load ranges, then application-specific performance is improved, but manufacturing cost and serviceability deteriorate
Solution Approach 1:
The motor-reducer assembly is designed as a universal platform that can serve multiple productivity levels by simply changing the drum size and cable guide configuration. This allows the manufacturer to produce a single base unit in high volume (reducing cost) while still meeting diverse load handling requirements through standardized accessory swaps.
Solution Approach 2:
The patent merges the common functional elements (motor, reducer, control circuitry) into a single standardized platform that serves all load ranges, while separating only the load-specific components (drum, cable guide). This merging strategy reduces manufacturing cost through economies of scale while maintaining the ability to handle different productivity requirements.
3Device complexity
If traditional cable guidance systems are used, then simplicity is maintained, but cable wrap integrity and positioning precision deteriorate
Solution Approach 1:
The patent replaces traditional mechanical cable guidance systems with a magnetic cable guide that uses magnetic fields to control cable positioning and maintain wrap integrity. This substitution improves cable placement precision and prevents cable derailment while adding minimal complexity to the overall system.
Solution Approach 2:
The cable guidance system utilizes changes in magnetic field parameters (strength, distribution) to control cable position and tension dynamically. This allows precise cable placement and maintains wrap integrity throughout the drum rotation cycle without complex mechanical guidance structures.
4Ease of manufacture
If fixed operator interface designs are used, then manufacturing simplicity is maintained, but adaptability and serviceability deteriorate
Solution Approach 1:
The operator interface incorporates a rotatable handle that can dynamically change its orientation and position during operation. This dynamic design allows the interface to adapt to different operator positions and preferences while maintaining a simple, standardized base structure that is easy to manufacture.
Solution Approach 2:
The operator interface allows changes in operational parameters such as handle angle, position, and rotation direction to be adjusted during use. This enables the same standardized interface to adapt to various operating conditions and user preferences without requiring multiple specialized designs.
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 cost-effective, reliable, and adaptable lift systems with improved load handling capacity, reduced operator effort, and enhanced serviceability through standardized components and remote monitoring, leading to increased efficiency and reduced downtime.
Implementation Method 1
an electrical motor for driving the actuator, the motor operating in response to control signals from the controller, to rotate a drum upon which a wire rope, with one end fixed to the drum, is wound and unwound
Implementation Method 2
a load sensor, attached to the frame, the load sensor sensing the load in response to a force applied to an unwound end of the wire rope
Implementation Method 3
optical proximity sensors
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
An improved electric lift actuator for use on a variety of lift systems, includes various improvements that enable a universal design with interchangeable parts across several load ranges. The universal design further enables additional features and functionality (e.g., improved load cell location, improved operator sensing and electrical signal/air channel in operator pendant (116), improved reliability and reduced cost for operator force sensing, etc.). In addition the universal design is incorporated with a rotational drive assembly wherein the load sensing and wire rope slack sensing, as well as cable limits may be achieved using improved components and techniques - such as non-contact sensors, etc. Many of the improvements described are believed to reduce cost and improve the performance and expand the capacity and reliability of the actuator in addition to making the actuator a common design across several applications and load ranges.