Air-Flap Apparatus Lever Linkage Failure Detection

Solution Overview

Problem

Existing air-flap apparatuses for motor vehicles face challenges in reliably detecting functional failures of individual air flaps without complicating the design or increasing costs, as they often continue to operate with damaged flaps due to shared drive systems and lack of additional sensors.

Innovation Solution

The air-flap apparatus incorporates an inner and outer lever arrangement, forming a four-joint linkage that allows for predictable misalignment of levers upon failure of an air flap, enabling detection of functional failures through physical engagement configurations without additional sensors, such as increased drive current or pressure, facilitating the detection of air flap damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional sensors are added to detect air flap failures, then detection reliability is improved, but device complexity and cost increase

Engineering Contradiction:

Improvedetection reliabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The coupling apparatus performs self-detection of air flap failures through its own mechanical structure. The levers and engagement configurations automatically detect failures without external sensors by generating detectable signals when air flaps are damaged or missing, allowing the system to monitor itself

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The coupling apparatus acts as an intermediary between the air flaps and the control system. It translates the physical state of air flaps into mechanical signals through its lever arrangements and engagement configurations, enabling indirect detection without direct sensor contact on each air flap

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If additional sensors are added to detect air flap failures, then detection reliability is improved, but manufacturing cost increases

Engineering Contradiction:

Improvedetection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The coupling apparatus performs self-detection of air flap failures through its own mechanical structure. The levers and engagement configurations automatically detect failures without external sensors by generating detectable signals when air flaps are damaged or missing, allowing the system to monitor itself

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The coupling apparatus serves multiple functions: it couples air flaps for coordinated movement and simultaneously detects failures. This multi-functionality eliminates the need for separate detection sensors, reducing component count and manufacturing cost while maintaining reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If a shared air-flap drive system is used for multiple air flaps, then device complexity is reduced, but detection of individual flap failures becomes difficult

Engineering Contradiction:

Improvedevice complexityVSAvoiddetection difficulty

Core Design Contradiction:

Device complexityVSDifficulty of detecting and measuring

Solution Approach 1:

The coupling apparatus is segmented into inner and outer lever arrangements with distinct engagement configurations. Each lever and engagement configuration is associated with specific air flaps, allowing localized detection of failures while maintaining the shared drive system structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling apparatus acts as an intermediary between the air flaps and the control system. It translates the physical state of air flaps into mechanical signals through its lever arrangements and engagement configurations, enabling indirect detection without direct sensor contact on each air flap

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS11370295B2OBD-capable air-flap apparatus

Publication Date: 2022.06.28 ROECHLING AUTOMOTIVE SE & CO KG

AI summary

An air-flap apparatus, encompassing an air-flap carrier having an air passage opening that is flowthrough-capable for air; at least three air flaps, each of which projects at least into the air passage opening and is received on the air-flap carrier movably between two operating positions with different degrees of coverage of the air passage opening; a coupling apparatus that couples the plurality of air flaps for movement together between their operating positions; and an air-flap drive system having an output member that is coupled to the at least three air flaps; the coupling apparatus includes an inner lever arrangement having at least one first lever, each first lever coupling exactly two air flaps associated with it for movement together between their operating positions; and that the coupling apparatus includes an outer lever arrangement having at least one second lever, each second lever coupling either a first lever and a single air flap not directly connected to the first lever, or two first levers, for movement together.