Active Controlled Flap System for Vehicle Airflow Management
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Solution Overview
Problem
Current vehicle systems lack efficient control over airflow to components such as heat exchangers, which can result in unnecessary airflow consumption and increased drag, as they often require variable airflow that existing systems cannot effectively manage.
Innovation Solution
An actively controlled flap system with rotatable flaps and sensors, actuated by a controller, which adjusts flap positions based on vehicle and environmental data to optimize airflow direction and quantity to heat exchangers and other vehicle components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If variable airflow components are used to selectively open or close airflow passages, then airflow control capability is improved, but device complexity increases
Solution Approach 1:
The system divides the airflow control function into multiple independent flaps (first flap, second flap with opening, third flap with opening) that can be controlled separately. Each flap can be positioned independently to regulate airflow to different heat exchangers, providing fine-grained control without requiring a completely complex variable geometry system.
Solution Approach 2:
The flaps are designed to be rotatable between multiple positions (fully open, partially open, fully closed) rather than fixed in place. This dynamic capability allows the system to adapt airflow control to varying operational conditions while maintaining a relatively simple mechanical structure compared to fully variable geometry systems.
2Measurement precision
If multiple flaps are used to control airflow direction, then airflow management precision is improved, but device complexity increases
Solution Approach 1:
The airflow control is segmented across multiple flaps positioned at different locations in the grille assembly. The first flap controls overall airflow, while the second and third flaps with openings provide additional control layers for directing airflow to specific heat exchangers, achieving precise airflow management through distributed control elements.
Solution Approach 2:
The flaps are arranged in a nested configuration where the second flap with its opening is positioned within or adjacent to the first flap, and the third flap with its opening is similarly nested. This nested arrangement allows multiple control functions to be integrated in a compact space, improving airflow management precision without proportionally increasing overall device complexity.
3Temperature
If airflow is continuously directed to heat exchangers, then cooling capability is improved, but energy consumption increases
Solution Approach 1:
The flaps can dynamically adjust their position based on thermal management requirements. When cooling demand is low, the flaps can be positioned to reduce or close airflow passages, minimizing parasitic airflow consumption. When cooling demand is high, the flaps open to maximize airflow to heat exchangers, providing adaptive thermal management that optimizes energy usage.
Solution Approach 2:
Different flaps can be positioned with different opening degrees to match local cooling requirements of different heat exchangers. This allows the system to direct airflow precisely where needed rather than providing uniform cooling across all components, reducing unnecessary airflow consumption in areas that do not require cooling.
Data Source
AI summary
An actively controlled flap system includes a bar defining a rotational axis, a first flap rotatably coupled to the bar and configured to rotate about the rotational axis, and a second flap rotatably coupled to the bar and configured to rotate about the rotational axis, the second flap including an opening extending through the second flap. The first flap is rotatable between a first position in which the opening in the second flap is covered by the first flap and a second position in which the opening in the second flap is uncovered, and the second flap is rotatable between a third position and a fourth position.