Active Air Flap Assembly with Elastic Restoring Mechanism
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Solution Overview
Problem
Conventional active air flap devices fail to operate when an actuator error occurs or power is disengaged, leading to increased engine and heat exchanger temperatures, which can cause vehicle errors.
Innovation Solution
An active air flap assembly featuring a plurality of flaps bonded by an elastic member, a roller, and an electromagnet, where the elastic member provides a restoring force and the electromagnet maintains the flaps' position, allowing automatic opening when the actuator fails or power is disengaged, preventing temperature increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an active air flap device uses an actuator to control the air flap opening angle, then the fuel efficiency is improved by reducing air resistance during high-speed operation, but the system reliability deteriorates when actuator error occurs or power is disengaged
Solution Approach 1:
The patent inverts the traditional control logic by using an electromagnet to hold the air flap in a closed position during normal operation, rather than using an actuator to actively open it. When power is disengaged or actuator error occurs, the elastic member automatically restores the air flap to the open position, ensuring system reliability while maintaining fuel efficiency during high-speed operation.
Solution Approach 2:
The system employs self-service through the elastic member that automatically restores the air flap to its initial open state when the electromagnet is de-energized. This eliminates the need for complex backup actuators or manual intervention, allowing the system to self-correct and maintain reliability without additional active components.
2Loss of energy
If the air flap is kept closed to reduce air resistance during high-speed operation, then fuel efficiency is improved, but the engine and heat exchanger temperatures increase causing vehicle errors
Solution Approach 1:
Instead of actively closing the air flap with an actuator, the system uses an electromagnet to actively close it only when needed for cooling. The default state is open, allowing natural airflow for cooling. The electromagnet overrides this default state temporarily when cooling is required, providing a simple fail-safe mechanism.
Solution Approach 2:
The elastic member is pre-loaded to store potential energy that can immediately restore the air flap to the open position when the electromagnet fails or power is lost. This beforehand preparation ensures that cooling airflow is restored without delay, preventing temperature increases and vehicle errors.
3Adaptability or versatility
If a conventional actuator system is used to control the air flap, then the opening angle can be adjusted for different operating conditions, but the device complexity increases and automatic opening capability is lost when power fails
Solution Approach 1:
The patent replaces the complex mechanical actuator system with a simpler electromagnet-based system. The electromagnet provides adaptive control during normal operation, while the elastic member provides the automatic opening capability without requiring complex mechanical fail-safe mechanisms or backup actuators.
Solution Approach 2:
The invention extracts the essential function of active control (electromagnet) from the complex actuator system, separating it from the passive restoring mechanism (elastic member). This simplification removes unnecessary complexity while maintaining adaptability and reliability.
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
Ensures stable operation of engine and heat exchangers by maintaining airflow even when actuator errors or power loss occur, preventing temperature rises and enhancing vehicle performance.
Implementation Method 1
an elastic member that bonds the plurality of flaps to form a preset angle with respect to each other
Implementation Method 2
an electromagnet disposed on the support bracket and the active air flap may be fixed to a close the aperture by the operation of the actuator when a current is supplied
Implementation Method 3
an actuator disposed on the support bracket and may be configured to rotate the roller to actuate the active air flap to an open or close the aperture
Data Source
AI summary
An active air flap is provided. The active air flap includes a plurality of flaps and an elastic member bonding the plurality of flaps to form a preset angle with respect to each other. The elastic member is insert-molded between the respective flaps and a roller is coupled to the top of the active air flap with a connection member and the active air flap is wound there around by a restoring force of the elastic member. Additionally, a support bracket that rotatably supports the roller through pins protrudes from a plurality of ends of the roller, and has an aperture formed therein and the active air flap is configured to open or close the aperture.