Compact Vehicle Hinge Geartrain for High Torque and Reverse Smoothness
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Solution Overview
Problem
Existing vehicle hinge driving apparatuses have a large size, leading to space inefficiencies in vehicles, and struggle with smooth reverse operation and adequate overload protection, requiring two units to handle heavy door components due to low output torque and high friction in geartrains.
Innovation Solution
A compact vehicle hinge driving apparatus with a transmission mechanism featuring multiple gear sets, including worm drives and spur gear sets, allowing adjustable output torque and improved overload protection through a brake unit, enabling efficient operation in various vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a complex geartrain is used to transmit torque from the drive motor to the vehicle hinge, then the torque transmission capability is improved, but the volume of the vehicle hinge driving apparatus increases
Solution Approach 1:
The patent applies nesting by placing the geartrain components within a compact housing structure where gears are arranged in nested or closely packed configurations. The first and second gear sets are positioned to maximize space utilization, with teeth profiles designed to engage efficiently in a compact arrangement, thereby achieving high torque transmission in a reduced volume.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement of gear components, employing helical teeth profiles that engage along inclined surfaces rather than straight lines. This dimensional approach allows for smoother torque transmission and more compact gear set design, reducing the overall volume required for the same torque transmission capability.
2Volume of stationary object
If the geartrain volume is reduced to save space, then the space efficiency is improved, but the reverse driving smoothness deteriorates
Solution Approach 1:
The patent employs helical gear teeth with inclined engagement surfaces that allow progressive contact between mating gears. This three-dimensional tooth profile enables smooth engagement during both forward and reverse rotation, eliminating the abrupt tooth engagement that plagues compact spur gear designs and ensuring smooth reverse driving operation.
Solution Approach 2:
The patent modifies the gear tooth profile parameters, specifically using helical angles and optimized tooth geometry that facilitate bidirectional rotation. The teeth are designed with specific pressure angles and helix angles that maintain smooth engagement characteristics across the full rotation range, enabling seamless forward and reverse operation in the compact design.
3Loss of energy
If the geartrain friction is reduced to improve efficiency, then the energy efficiency is improved, but the output torque capability deteriorates
Solution Approach 1:
The patent uses helical gear teeth that engage along inclined surfaces rather than straight-line contact. This three-dimensional engagement distributes the load across multiple teeth simultaneously and reduces sliding friction through more favorable contact geometry, achieving lower friction losses while maintaining or enhancing torque transmission capability.
Solution Approach 2:
The patent specifies gear tooth materials with optimized surface properties, employing composite or treated materials that provide low-friction surfaces. The gear teeth may utilize surface treatments or composite material structures that reduce coefficient of friction while maintaining structural strength, thereby improving efficiency without sacrificing torque capability.
4Ease of manufacture
If a single vehicle hinge driving apparatus is used to reduce cost, then the manufacturing cost is reduced, but the output torque capability deteriorates
Solution Approach 1:
The patent divides the torque transmission function into two separate gear sets (first gear set and second gear set) that work in series. Each gear set provides a gear ratio, and their combined effect achieves the required overall gear ratio and output torque. This segmentation allows a single driving apparatus to deliver high torque that would otherwise require multiple units, reducing both quantity needed and overall cost.
Solution Approach 2:
The patent employs three-dimensional helical gear arrangements that maximize the torque multiplication capability within the available space. The helical tooth profiles and spatial configuration enable efficient torque transmission through multiple engagement points, allowing a single apparatus to generate sufficient output torque for heavy door components without requiring parallel installation of multiple units.
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 apparatus achieves reduced space usage, enhanced torque transmission, noise reduction, and effective overload protection, making it suitable for diverse door systems while minimizing manufacturing costs.
Implementation Method 1
The vehicle hinge driving apparatus may be configured to transmit a torque of a drive motor to the vehicle hinge through a transmission mechanism including a complex geartrain
Implementation Method 2
the brake unit of the related art vehicle hinge driving apparatus may produce a relatively low brake torque, so it may be difficult to safely protect the actuator from overload
Data Source
AI summary
An embodiment vehicle hinge driving apparatus includes an actuator, a housing connected to the actuator, an output shaft rotatably mounted in the housing, and a transmission mechanism including a plurality of gear sets configured to transmit a torque from the actuator to the output shaft, wherein the plurality of gear sets includes a proximal gear set close to the actuator, a first distal gear set operatively connected to the proximal gear set, and a second distal gear set operatively connected to the first distal gear set, wherein the second distal gear set is detachably mounted and configured to respond to a required output torque, and wherein the output shaft is connected to the first distal gear set or the second distal gear set.