Retractable Aerodynamic Flap Locking for Gear Stress Relief
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Solution Overview
Problem
Existing retractable aerodynamic systems for vehicles face issues with high stress and fatigue on gear components due to aerodynamic forces, leading to potential damage and inefficiency, particularly in high-speed conditions, and existing solutions either require complex and costly energy compensation or disengagement mechanisms.
Innovation Solution
A retractable aerodynamic system with a locking member that securely locks the flap in an indexed position, using a spring element and housing assembly to transmit forces to the vehicle structure, reducing stress on the drive means and allowing for efficient aerodynamic performance without continuous energy supply, and incorporating a disengagement member for protection during exceptional conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the aerodynamic flap is given a large surface area to effectively limit air flow under the vehicle, then the aerodynamic performance is improved, but the forces and torque experienced by the flap increase significantly, leading to high stress on the worm screw and gear
Solution Approach 1:
The locking member is pre-positioned to engage with the shaft at the indexed position before aerodynamic forces fully act on the flap. This preliminary engagement ensures that when the flap reaches the desired position, the locking member is already in place to immediately承接 the aerodynamic forces, preventing excessive stress on the drive means components.
Solution Approach 2:
The locking member acts as an intermediary between the aerodynamic flap and the vehicle structure. It transfers the high aerodynamic forces directly to the structure rather than allowing them to pass through the vulnerable worm screw and gear components, thus protecting the drive means while maintaining effective aerodynamic function.
2Reliability
If a permanent force is applied by the drive means to compensate for small rotations of the flap, then the flap maintains its aerodynamic function, but the drive means must be supplied with energy permanently and the stress and fatigue on gear teeth are not solved
Solution Approach 1:
Instead of continuous energy supply, the system uses periodic action where the drive means operates only during positioning to engage the locking member. Once locked, the aerodynamic forces are borne by the locking member and structure, allowing the drive means to remain stationary without continuous energy consumption while maintaining flap position stability.
Solution Approach 2:
The locking function is extracted from the drive means and implemented as a separate locking member mechanism. This separation allows the drive means to focus only on positioning the flap to the indexed position, while the locking member handles the continuous force-bearing function, eliminating the need for permanent energy supply to the drive means.
3Strength
If a disengagement member is used to disconnect the drive means and shaft to protect against forces, then the drive means is protected, but freedom of rotation is introduced between the shaft and drive means, allowing vibrations to rotate the worm screw and flap
Solution Approach 1:
The locking member combines both protection and stability functions in a single integrated mechanism. It protects the drive means by承接 aerodynamic forces while simultaneously preventing unwanted rotation through positive engagement with the shaft at the indexed position, eliminating the need for separate disengagement mechanisms that would compromise stability.
Solution Approach 2:
The locking member functions as a composite solution combining elements of both rigid connection (for stability) and force isolation (for protection). It maintains a rigid connection between shaft and flap at the locked position to prevent vibrations from causing rotation, while isolating the drive means from high aerodynamic forces through the locking mechanism.
4Strength
If the locking member transmits all forces to the structure, then stress on drive components is reduced, but the locking member itself experiences high stress requiring robust design
Solution Approach 1:
The locking member uses a simplified geometric replication approach where the shaft's external cylindrical surface is copied as the internal surface of the locking member's housing cavity. This copying creates a natural positive engagement interface that provides both locking and force transmission functions without requiring complex internal mechanisms, reducing overall design complexity while maintaining strength.
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 effectively reduces stress on drive components, enhances the robustness of the system, and optimizes aerodynamic performance by securely locking the flap in the desired position, minimizing the risk of damage and energy consumption, while maintaining flexibility and ease of implementation.
Implementation Method 1
a locking member (5) for locking the aerodynamic flap (4) in an indexed position with respect to the structure (7) of the vehicle, the locking member (5) being able to transmit forces experienced by the aerodynamic flap (4) to the structure (7) of the vehicle when the aerodynamic flap (4) is locked in the indexed position
Implementation Method 2
the locking member (5) being able to transmit forces experienced by the aerodynamic flap (4) to the structure (7) of the vehicle
Data Source
AI summary
The invention provides a retractable aerodynamic system for a motor vehicle including a structure of the vehicle. The system includes at least one aerodynamic flap, a drive mechanism that can rotate the aerodynamic flap about a rotation axis, and at least one member for locking the aerodynamic flap in at least one indexed position with respect to the structure of the vehicle. The locking member is able to transmit forces experienced by the aerodynamic flap to the structure of the vehicle when the aerodynamic flap is locked in the indexed position.