Air Influencing Element Adjustment with Mechanical Failsafe Coupling
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Solution Overview
Problem
Existing adjustment devices for air influencing elements in motor vehicles are often bulky, expensive, and unreliable due to the use of tolerance-sensitive parts and complex magnetic couplings, which can lead to increased fuel consumption and potential damage from obstacles.
Innovation Solution
A compact and cost-effective adjustment device with a failsafe mechanism that engages the first part of the driving unit, utilizing a transmission ratio to reduce forces and incorporate an auxiliary driving motor for reliable operation, replacing expensive magnetic couplings and allowing for adjustable air influencing elements like air inlets, spoilers, and wings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic couplings are used in the adjustment device, then the device can operate reliably, but the device becomes bulky and expensive
Solution Approach 1:
The patent replaces the magnetic coupling system with a purely mechanical transmission system consisting of a drive gear, driven gear, and shaft connections. This mechanical substitution eliminates the need for complex magnetic couplings while maintaining reliable power transmission from the electric motor to the adjustment mechanism, thereby reducing device volume and cost.
Solution Approach 2:
The patent extracts and removes the magnetic coupling components from the adjustment device design. By eliminating this specific subsystem, the overall device volume is reduced and manufacturing costs are lowered, while the core reliability function is maintained through the simplified mechanical transmission path.
2Manufacturing precision
If tolerance-sensitive parts are used in the adjustment device, then the device can achieve precise adjustment, but the device becomes expensive and less reliable
Solution Approach 1:
The patent changes the tolerance parameters of the mechanical components to standard, easily manufacturable values. The gear teeth, shafts, and mounting features are designed with conventional tolerances that can be achieved through standard manufacturing processes, eliminating the need for expensive precision machining while maintaining sufficient adjustment accuracy for the application.
Solution Approach 2:
The patent uses homogeneous materials and standardization across components. Common materials like steel or aluminum alloys are used throughout, and standard fasteners, gears, and mounting features are employed. This homogeneity simplifies manufacturing and reduces costs while maintaining consistent performance across all parts of the adjustment device.
3Reliability
If complex magnetic couplings are used in the adjustment device, then the device can function properly, but the device becomes expensive
Solution Approach 1:
The patent replaces expensive magnetic coupling components with simple mechanical connections including gears, shafts, and bearings. This substitution dramatically reduces manufacturing cost while maintaining functional reliability through direct mechanical power transmission from the motor to the adjustment mechanism, eliminating the need for complex magnetic field management.
Solution Approach 2:
The patent employs inexpensive, easily replaceable mechanical components in place of costly magnetic couplings. These simple mechanical parts can be manufactured at low cost and are readily available, making the overall adjustment device more affordable while maintaining adequate reliability for the intended application lifecycle.
4Loss of energy
If the air inlet is kept closed to lower air resistance, then fuel consumption decreases, but the motor operating temperature may run too high
Solution Approach 1:
The patent implements a dynamic adjustment mechanism that allows the air inlet to change its opening degree continuously based on real-time operating conditions. The electric motor drives the adjustment mechanism to optimize the balance between air resistance and cooling requirements, enabling the system to adapt dynamically rather than remaining statically closed or open.
Solution Approach 2:
The patent incorporates a control system that monitors motor operating temperature and air resistance conditions, then provides feedback to adjust the air inlet opening degree accordingly. When temperature rises above optimal levels, the system automatically increases the opening to improve cooling; when cooling is sufficient, it reduces the opening to minimize air resistance and fuel consumption.
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 provides a reliable, compact, and cost-effective adjustment device that ensures efficient fuel consumption by adjusting air influencing elements to optimal positions, while minimizing damage from obstacles through a lighter and more reliable failsafe mechanism.
Implementation Method 1
auxiliary driving motor (9) which, separately from a main driving motor (13) of the driving unit (3), is configured for merely driving the failsafe mechanism (8)
Implementation Method 2
planetary gear system (17) comprising a sun gear (16b), at least one planet gear (18), a planet carrier (19) and a ring gear (20)
Implementation Method 3
the forces on the first part of the driving unit are smaller than on the second part, with the output shaft (6), with the output shaft (6) approximately parallel to the input shaft (15)
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Adjustment device for adjusting an air influencing element of a motor vehicle between at least a first position and a second position, comprising a driving unit for adjusting the air influencing element between at least the first position and the second position, provided with an input shaft and an output shaft which is at a distance from the axis of the input shaft, wherein the driving unit has a first part which is provided around the input shaft of the driving unit, and has a second part which is provided around the output shaft of the driving unit, wherein the adjustment device is furthermore provided with a failsafe mechanism, wherein the failsafe mechanism engages the first part of the driving unit.