Active Grille Bracket Assembly With Fastener-Free Actuator Mounting
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Solution Overview
Problem
Current cooling systems for automobiles are inefficient, particularly at start-up, as they remove heat from the engine when it needs to reach optimal operating temperature quickly, and they often require numerous fasteners for actuator connection to the grille, leading to aerodynamic inefficiencies and increased labor time.
Innovation Solution
A bracket design that connects multiple pieces without fasteners, featuring alignment and attachment features to support an actuator and louvers, simplifying design, tooling, and reducing components, allowing for efficient airflow management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional actuators are connected to the grille using multiple fasteners, then the connection is secure and reliable, but the device complexity and labor time increase
Solution Approach 1:
The actuator is integrated directly with the grille structure, merging two previously separate components. The actuator housing serves as both the actuator enclosure and the grille attachment structure, eliminating the need for separate fasteners and reducing assembly complexity while maintaining connection reliability
Solution Approach 2:
A integrated mounting structure acts as an intermediary between the actuator and grille, providing a unified attachment mechanism that combines the functions of both components and eliminates the need for multiple discrete fasteners
2Temperature
If cooling systems remove heat from the engine during operation, then cooling efficiency is improved, but the engine cannot reach optimal operating temperature quickly at start-up
Solution Approach 1:
The louver system dynamically adjusts airflow based on engine temperature conditions. At start-up, louvers remain closed to prevent heat removal and allow the engine to reach optimal temperature quickly. During operation, louvers open to enable heat removal and maintain cooling efficiency, creating a dynamic response to changing thermal conditions
Solution Approach 2:
The system uses temperature feedback from the engine to control louver position. When the engine is cold, sensors detect low temperature and keep louvers closed to retain heat. When the engine reaches optimal temperature, feedback signals open the louvers for heat removal, creating a closed-loop control system that adapts to thermal conditions
3Productivity
If vehicle components are designed for optimal cooling when new, then cooling performance is maximized, but the system becomes inefficient after significant mileage due to wear and tear
Solution Approach 1:
The active louver system dynamically adjusts airflow patterns based on real-time thermal conditions and engine requirements. This dynamic capability allows the system to compensate for wear and aging by adapting airflow optimization strategies, maintaining cooling efficiency throughout the vehicle's service life rather than degrading with mileage
Solution Approach 2:
The system changes operational parameters such as louver angle, airflow velocity, and distribution patterns to optimize cooling under different conditions. These parameter adjustments allow the system to maintain effective cooling performance despite component wear and aging by adapting to changing system characteristics
Data Source
AI summary
A modular a bracket which forms a cavity such that the bracket surrounds and supports an actuator. In one embodiment, the bracket is made of multiple pieces and also connects together without the use of fasteners. The pieces are connected together through the use of several attachment features, with a portion of each of the attachment features integrally formed as part of each half. The bracket also includes a plurality of alignment features integrally formed as part of the bracket. The alignment features support and properly position the actuator within the cavity. The design of the bracket reduces and simplifies design and tooling, and also has minimal components and fasteners, which also simplifies and reduces labor time.