Active Air Flap Linkage for Sequential Vehicle Grille Control
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Solution Overview
Problem
Existing active air flaps for vehicles face issues with increased torque requirements for actuators due to simultaneous rotation of multiple flap members, leading to potential twisting and inefficiencies in aerodynamic performance and cooling efficiency.
Innovation Solution
The active air flap features a frame unit with guide grooves and a link unit that allows flap members to be sequentially operated, using a drive unit with an actuator and rack-and-pinion mechanism to control flap movement, and includes a fixing unit to prevent twisting and pushing due to aerodynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If multiple flap members are rotated simultaneously by an actuator, then the outside air inlet can be opened or closed quickly, but the torque requirement of the actuator increases significantly
Solution Approach 1:
The patent divides the simultaneous rotation of multiple flap members into sequential rotation. The link unit is designed to rotate flap members one by one in a predetermined sequence rather than all at once. This segmentation reduces the peak torque requirement of the actuator while maintaining the overall operation speed, as each flap member is rotated individually through controlled linkages.
Solution Approach 2:
The link unit performs preliminary positioning and force distribution before the actuator applies full rotational force. The mechanical linkage structure prepares the system by aligning and pre-loading the flap members in sequence, allowing the actuator to apply torque more efficiently to each individual flap member rather than overcoming the combined resistance of all flaps simultaneously.
2Loss of energy
If flap members are operated to close the outside air inlet for reducing air resistance, then fuel efficiency improves, but cooling efficiency may deteriorate when the engine room is overheated
Solution Approach 1:
The patent implements dynamic control of the flap members where their opening/closing state can be adjusted in real-time based on vehicle operating conditions. The system can transition from a fully closed position (for aerodynamic efficiency) to a partially or fully open position (for cooling) depending on engine temperature, airflow requirements, and driving conditions. This dynamic adaptability allows the system to optimize between fuel efficiency and cooling efficiency as needed.
Solution Approach 2:
The system changes the operational parameters of the flap members based on different vehicle conditions. By adjusting the degree of opening/closing, rotation speed, and sequence of operation, the system can adapt to varying requirements for aerodynamic performance and engine cooling, transforming a static binary state into a dynamically adjustable parameter set.
3Device complexity
If a simple link unit is used to transmit driving force, then device complexity is reduced, but flap members may be pushed or twisted by aerodynamic forces
Solution Approach 1:
The link unit incorporates asymmetric structural features and positioning mechanisms that are specifically designed to counteract aerodynamic forces. The linkages are positioned and dimensioned to provide optimal mechanical advantage and stability against push and twist forces during operation, rather than using a symmetric or overly simplified structure.
Solution Approach 2:
The link unit acts as an intermediary mechanical structure between the actuator and the flap members, providing force transmission while also offering structural support and stability. The linkages serve as mediating elements that can absorb and redirect aerodynamic forces, protecting the flap members from direct pushing and twisting while maintaining the simplicity of the overall system.
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 design enhances aerodynamic performance and cooling efficiency by optimizing flap operation, reducing air resistance, and improving fuel efficiency while maintaining structural integrity under various conditions.
Implementation Method 1
The drive unit includes an actuator having a drive shaft, a driving pinion gear rotating in conjunction with the drive shaft, and a rack reciprocating vertically on the vertical frame along with the rotation of the driving pinion gear.
Implementation Method 2
The vertical frame includes a first guide groove having a straight section and a curved section extending as a single path and configured to guide each of the flap members on a opening/closing path
Data Source
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AI summary
Disclosed herein is an active air flap for vehicles, which includes a frame unit having a hollow structure in which horizontal and vertical frames thereof are connected to each other, and configured to fluidly communicate with an outside air inlet of a grill, a flap unit having a plurality of flap members rotatably connected to the frame unit and configured to open and close the outside air inlet, a drive unit configured to provide a driving force to the flap unit, and a link unit connected between the flap unit and the drive unit to transmit the driving force from the drive unit to the flap unit.