Active Air Flap Segmented Control for Cooling Drag Trade-off
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Solution Overview
Problem
Existing cooling systems face challenges in stabilizing cooling water temperature during high-temperature exhaust conditions, limiting their ability to improve exhaust gas purifying capability without increasing component capacity or size, which affects both cooling performance and fuel economy.
Innovation Solution
An active air flap system with selectively controllable first and second air flaps, guided by an air guide, that adjusts airflow based on vehicle speed, outside temperature, refrigerant pressure, and cooling water temperature to optimize airflow to the radiator module, thereby enhancing cooling performance and reducing aerodynamic resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the area of the opening is increased to increase air flow rate and heat dissipation, then cooling performance is improved, but aerodynamic coefficient increases and driving resistance becomes large
Solution Approach 1:
The patent applies dynamics by making the air flap movable rather than fixed. The air flap can dynamically adjust its opening area based on cooling demands, allowing the system to optimize between cooling performance and aerodynamic resistance in real-time. The control unit adjusts the air flap position according to cooling water temperature and vehicle speed, enabling adaptive control that resolves the contradiction between maintaining large opening for cooling and small opening for low drag.
Solution Approach 2:
The patent changes the parameter of opening area from fixed to variable. By controlling the air flap to adjust the opening area dynamically, the system can change the parameter according to operating conditions. When cooling demand is high, the opening area increases; when cooling demand is low, the opening area decreases, thus resolving the contradiction between cooling performance and aerodynamic resistance.
2Productivity
If the hardware specifications of the radiator module and fan motor are improved to increase cooling capacity, then cooling performance is improved, but component capacity and size cannot be increased indefinitely due to complex engine room layout and cost and weight increase
Solution Approach 1:
Instead of increasing radiator or fan motor specifications, the patent changes the parameter of air flow control by introducing a movable air flap. This allows the existing cooling components to operate more efficiently by optimizing air intake, thereby improving cooling capacity without increasing component size or complexity.
Solution Approach 2:
The air flap system enables self-regulation of cooling performance based on actual cooling demands. The control unit monitors cooling water temperature and vehicle speed, then automatically adjusts the air flap position to provide optimal air flow, allowing the cooling system to self-optimize without requiring larger or more complex components.
3Device complexity
If a single air flap is used to control airflow, then the structure is simple, but the control precision and adaptability to different cooling zones are limited
Solution Approach 1:
The patent divides the single air flap control into multiple segmented flaps (first air flap and second air flap) that can be controlled independently. Each flap can be adjusted according to different cooling demands in different zones, improving adaptability while maintaining relatively simple structure. The first air flap corresponds to the central opening and the second air flap corresponds to the side opening, allowing differentiated control.
Solution Approach 2:
The patent applies local quality by providing different control strategies for different opening zones. The central opening (controlled by first air flap) and side opening (controlled by second air flap) can have different opening areas based on local cooling demands. This allows the system to optimize air flow distribution to different parts of the radiator according to specific cooling requirements.
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 system improves cooling performance by increasing airflow when needed and reduces fuel consumption by minimizing airflow when cooling demands are low, thus achieving better fuel economy without increasing component size or capacity.
Implementation Method 1
an air guide configured to guide air introduced in the ventilation opening toward the first air flap and the second air flap
Implementation Method 2
the heat dissipation rate of the radiator is increased, thereby improving cooling performance
Data Source
AI summary
An active air flap includes: a first air flap disposed between a ventilation opening of a bumper and a radiator, and openably disposed in a first section facing the radiator; a second air flap disposed between the ventilation opening of the bumper and the radiator, and openably disposed in a second section bordering the first section facing the radiator; and an air guide configured to guide air introduced into the radiator toward the first air flap and the second air flap.