Adjustable Air Deflector Assembly with Lever-Link Actuation
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Solution Overview
Problem
Existing air deflector assemblies for trucks and tractors are cumbersome, costly, and pose safety risks due to their weight, complexity, and the need for manual adjustment, which often results in inefficient aerodynamic performance and increased fuel costs.
Innovation Solution
An adjustable air deflector assembly with a support frame, a pivotally mounted deflector panel, and a positioning mechanism using a lever, link, and linear actuator that allows for easy adjustment from the cab, reducing the need for heavy reinforcements and expensive actuators, featuring a self-braking screw thread mechanism for convenient and accurate operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a central actuator with substantial reinforcements is used to move the deflector panel, then the deflector panel can resist operating forces and wind loads, but the weight and complexity of the assembly increases substantially
Solution Approach 1:
Instead of having the actuator directly support the full weight and forces of the deflector panel, the invention inverts the support strategy by using the hinged lever-link mechanism to distribute and redirect forces. The actuator only needs to provide the force to change the angle of the mechanism, while the hinge member and link structure naturally support the panel's weight and resist wind loads through their geometric arrangement.
Solution Approach 2:
The hinge member acts as an intermediary between the actuator and the deflector panel. It transmits and transforms the actuator's linear motion into angular movement of the lever and link, while also serving as a structural element that supports the panel's weight and distributes forces throughout the mechanism, reducing the burden on the actuator.
2Device complexity
If manual adjustment with a telescopic strut and locking pin is used, then the mechanism is simple and low cost, but the driver must climb to the roof to manually support the heavy panel while adjusting
Solution Approach 1:
The invention replaces the manual telescopic strut mechanism with a hinged lever-link system actuated by a linear actuator. This substitution eliminates the need for manual support of the heavy panel during adjustment, as the actuator automatically provides the necessary force to move the panel through the lever-link mechanism, while maintaining relative mechanical simplicity.
Solution Approach 2:
The positioning mechanism is self-servicing in that the actuator automatically provides the force needed to overcome the panel's weight and move it to the desired position. The hinged lever-link mechanism naturally maintains the panel in position without requiring manual intervention or complex locking mechanisms, as the geometry of the system provides inherent stability.
3Productivity
If remote control by electric or pneumatic actuator is used, then the frequency and accuracy of adjusting is improved, but the weight and cost increase substantially
Solution Approach 1:
The invention changes the operational parameters of the actuation system by using a lightweight linear actuator with a screw-threaded shaft mechanism. This provides accurate positioning through the self-braking property of the screw threads, which maintains the panel in position without requiring continuous power, while keeping the system weight low compared to electric or pneumatic actuators.
Solution Approach 2:
The invention uses a simple screw-threaded linear actuator mechanism that is lighter and less expensive than electric or pneumatic actuators. While potentially less sophisticated, this mechanism provides sufficient accuracy for the application and can be easily replaced or adjusted if needed, offering a cost-effective alternative.
4Weight of moving object
If the hinge member is associated with an intermediate location on the lever or link, then the actuator weight and forces are fully supported by the hinged lever and link, but the mechanism becomes more complex
Solution Approach 1:
The invention introduces a spatial dimension to the force distribution by positioning the hinge member at an intermediate location on the lever or link rather than at the endpoint. This geometric arrangement creates a triangular force distribution pattern that naturally directs the actuator's weight and forces through the lever-link structure to the mounting points, reducing the burden on any single component.
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 solution reduces the effort and cost of adjusting the air deflector, enhances safety, and improves aerodynamic efficiency by allowing easy and precise adjustment of the deflector panel from a convenient location, eliminating the need for heavy and costly actuators while maintaining accurate positioning.
Implementation Method 1
a lever having a first lever end and a second lever end, the first lever end being pivotally arranged on the support frame; a link having a first link end and a second link end, the first link end being pivotally linked to the deflector panel; a hinge member pivotally connecting the lever and the link to one another; and a linear actuator having first and second pivotal connecting ends being arranged for altering an angle defined between the lever, the link, and the hinge member
Implementation Method 2
featuring a self-braking screw thread mechanism for convenient and accurate operation
Data Source
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AI summary
An air deflector assembly (3) is suitable for mounting on a roof (2) of a motor vehicle having a driver cab (1) with a substantially vertical rear wall (13). The air deflector assembly (3) includes a support frame (23) for mounting to the roof (2) of the driver cab (1). The assembly (3) further includes a deflector panel (9) adjustably supported by the support frame (23), and a positioning mechanism permitting the deflector panel (9) to be moved between a retracted position and a selected one of several deflecting positions. A forward edge of the deflector panel (9) is pivotally mounted to the support frame (23). The positioning mechanism comprises a lever (57) with a first lever end and a second lever end (69). The first lever end being pivotally arranged on the support frame by a transverse shaft (55). A link (61) having a first link end (65) and a second link end (66), has its first link end (65) pivotally linked to the deflector panel (9) by means of a hinge bracket (73). A hinge member (67) pivotally connects the lever (57) and the link (61) to one another. A linear actuator (75) has first and second pivotal connecting ends (101, 77) and is arranged for altering an angle defined between the lever (57), the link (61), and the hinge member (67). One of the hinge member (67) and a pivotal attachment of the second pivotal connecting end (77) of the linear actuator (75) is associated with a location on one of the lever (57) and the link (61) intermediate of the respective first and second lever end (69) or the first and second link end (65, 66). [Figure 3]