Window Chain Actuator Gear Assembly for High-Load Durability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing motor drives for windows, particularly those with high push-force requirements, face durability issues due to limitations in plastic double gears, and alternative stronger gears are either expensive or complex to manufacture, necessitating a solution that balances durability and cost-effectiveness.
Innovation Solution
A push-pull chain actuator with a gear train comprising a driving gear and a driven double gear, where the input and output gears have non-circular engagement structures, allowing for rotational locking and enabling the use of different materials for each gear to optimize durability and production costs, with the input gear made from plastic and the output gear from metal for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a moulded plastic double gear is used, then manufacturing cost is reduced, but strength and durability are insufficient for high push-force requirements
Solution Approach 1:
The double gear is divided into two separate gears (input gear and output gear) that are manufactured independently and then assembled together. This allows each gear to be optimized for its specific function and material requirements, with the input gear being cost-effective plastic and the output gear being high-strength metal.
Solution Approach 2:
Different materials are used for different parts of the gear system based on local requirements. The input gear uses plastic for cost-effectiveness where high strength is not critical, while the output gear uses metal for high strength where it is needed to handle the thrust chain forces.
2Strength
If alternative stronger gears are used to replace plastic double gears, then strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
By segmenting the double gear into separate input and output gears, the manufacturing process is simplified. Each gear can be manufactured using standard, well-established processes for single gears, avoiding the complexity of manufacturing a single integrated double gear with varying strength requirements.
Solution Approach 2:
The solution uses a composite approach by combining plastic and metal materials in a multi-component gear system. This allows each component to be manufactured using its optimal material and process, rather than requiring a single complex material or process for the entire double gear.
3Ease of manufacture
If a single material is used for the double gear, then manufacturing is simplified, but durability under varying load conditions is compromised
Solution Approach 1:
The gear system uses different materials for the input and output gears based on their specific functional requirements. The plastic input gear handles lower-stress conditions, while the metal output gear handles high-stress conditions from the thrust chain, optimizing durability for each local condition.
Solution Approach 2:
The solution employs composite materials by combining plastic and metal in the gear system. This allows the system to achieve both manufacturing simplicity (through separate manufacturing of standard components) and high reliability (through material optimization for each component's specific load conditions).
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present invention relates to an electrical window actuator (15) for operating windows (21), particularly to an electric push-pull chain actuator and the internal gear train of such an actuator. The push-pull chain actuator comprises an electric motor (1) and a gear train arranged to be driven by the electric motor and to push and pull a thrust chain (2). The gear train comprises a driving gear (3) a driven double gear comprising an input gear (5) and an output gear (6). The input gear (5) comprises a centre hole having an internal non-circular engagement structure (9) arranged at the inside circumference. The output gear (6) comprises an external non-circular engagement structure (10) arranged coaxially with the input and output gears and engaging with the internal engagement structure (9) to rotatably lock the input gear to the output gear.