Vehicle Closure Actuator Floating-Rotor Brake for Incline Holding
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Solution Overview
Problem
Existing vehicle closure actuators face challenges in providing consistent and efficient power operation across varying vehicle inclinations, and they often require continuous power to maintain closure positions, leading to inefficiencies and increased energy consumption.
Innovation Solution
A power closure actuator with an integrated brake-clutch unit that includes a shaft with a brake device and a clutch, featuring an axially floating rotor and passive backing brake clamp, allowing for variable braking force application and independent operation from vehicle inclination, enabling efficient power management and consistent closure control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous power is applied to maintain closure positions, then the closure position stability is improved, but energy consumption increases
Solution Approach 1:
The brake device is configured to automatically engage and maintain closure positions without requiring continuous power input. The spring-loaded brake clamp applies constant braking force to the shaft, allowing the actuator to hold the closure in place passively, thereby eliminating the need for continuous electrical power while maintaining position stability.
Solution Approach 2:
The brake device operates in periodic cycles rather than continuously - engaging when power is removed to maintain position, and disengaging only when power is reapplied to move the closure. This intermittent operation pattern significantly reduces energy consumption compared to continuous power application while ensuring closure position is maintained during idle periods.
2Reliability
If brake force is increased to maintain closure positions on inclined surfaces, then position stability is improved, but the risk of unintended movement during operation increases
Solution Approach 1:
The brake device incorporates a spring-loaded brake clamp that dynamically adjusts braking force based on operational conditions. During motor-driven movement, the system can temporarily reduce brake force to allow smooth operation, then automatically increases braking force when movement stops to maintain position on inclines. This dynamic adjustment eliminates unintended movement during operation while ensuring stability when stationary.
Solution Approach 2:
The brake device is pre-configured with spring loading that prepares the braking force in advance. Before the closure reaches its final position or before the motor stops, the brake clamp is already positioned and loaded to engage immediately, ensuring smooth transition from motor-driven movement to brake-held position without unintended movement or shocks.
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 actuator provides consistent closure operation regardless of vehicle inclination, reduces energy consumption by allowing the brake to maintain closure positions without continuous power, and enhances user control through variable braking force settings.
Implementation Method 1
the axially floating rotor is biased away from the passive backing brake clamp by a first biasing member. Deflection of the first biasing member coupled with axial movement of the active brake clamp and the axially floating rotor is configured to enable application of the braking force
Implementation Method 2
an axially floating rotor configured for rotation with the shaft, the axially floating rotor having a first axial side facing the active brake clamp and providing a first braking surface for frictional contact therewith
Data Source
AI summary
A power closure actuator for powering a movable closure includes a shaft situated between an electric motor and an output member. A brake device along the shaft is configured for actuation via an electric brake actuator to apply braking. An active brake clamp is movable by the electric brake actuator. An axially floating rotor is rotatable with the shaft and has a first axial side facing the active brake clamp a second axial side providing a second braking surface. A passive backing brake clamp is positioned adjacent the second braking surface. The axially floating rotor is biased away from the passive backing brake clamp by a first biasing member. Deflection of the first biasing member coupled with axial movement of the active brake clamp and the axially floating rotor enables braking by pinching action of the axially floating rotor between the active brake clamp and the passive backing brake clamp.