Cam Disc Coupling for Vehicle HVAC Flap Actuation
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Solution Overview
Problem
Modern air conditioning systems for vehicles require additional control elements and motors to fully utilize the degree of freedom introduced by the evaporator bypass flap, leading to increased installation space, weight, and costs, while existing solutions mechanically couple the temperature mixing flap with the evaporator bypass flap, complicating the regulation of interior vehicle temperature.
Innovation Solution
Mechanical connection of the temperature mixing flap and evaporator bypass flap via a cam disc with a cam groove and lever arrangement, allowing for forced coupling of their movements with a single actuator, reducing the need for additional motors and optimizing the use of the evaporator bypass flap's degree of freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the evaporator bypass flap is used to regulate interior temperature, then temperature control flexibility is improved, but the number of required control elements and motors increases
Solution Approach 1:
The patent combines the control of the evaporator bypass flap and temperature mixing flap into a single integrated control mechanism. The cam disc with cam groove receives a single actuating signal and mechanically coordinates both flaps, reducing the number of independent motors and control elements while maintaining temperature control flexibility through the coordinated movement of both flaps.
Solution Approach 2:
The cam disc mechanism serves multiple functions: it controls both the evaporator bypass flap and temperature mixing flap, translates rotational movement into coordinated flap positioning, and enables temperature regulation across different operating ranges using a single control system. This multi-functionality reduces overall system complexity while maintaining adaptability.
2Weight of stationary object
If the temperature mixing flap and evaporator bypass flap are mechanically coupled, then installation space and weight are reduced, but the regulation of interior vehicle temperature becomes more complex
Solution Approach 1:
The mechanically coupled flap system provides self-service by automatically coordinating the position of the evaporator bypass flap and temperature mixing flap based on a single control input. The cam groove geometry is designed to automatically position both flaps in appropriate configurations for different temperature ranges without requiring complex electronic control logic, thereby simplifying operation despite the mechanical coupling.
3Measurement precision
If additional motors are installed for independent flap control, then temperature regulation precision is improved, but energy consumption and noise increase
Solution Approach 1:
The patent merges the actuation of two flaps into a single motor-driven cam disc system. This reduces energy consumption by eliminating redundant motors while maintaining temperature regulation precision through the mechanical coordination provided by the cam groove, which ensures both flaps are positioned correctly for the desired temperature range.
Solution Approach 2:
The cam disc acts as an intermediary mechanism that translates a single motor's rotational movement into coordinated positioning of both flaps. This intermediary mechanism enables precise temperature control through mechanical leverage and geometric design without requiring multiple independent motors, thereby reducing energy consumption and noise while maintaining control precision.
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
This solution simplifies temperature regulation by allowing variations in interior temperature to be controlled solely by the evaporator operation below a lower limit temperature, and by the evaporator bypass flap between limit temperatures, reducing energy consumption and noise, and extending the range in electric or hybrid vehicles.
Implementation Method 1
an evaporator of a refrigerant circuit through which at least parts of the air flow can flow
Implementation Method 2
a heating heat exchanger through which at least parts of the air flow can flow
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The device (10) has an intake channel (18) for introduction of airflow, and a heat exchanger (16) arranged behind a vaporizer (14) for flowing the air. Amount of the air flowing through the vaporizer of a refrigerant cycle and a pivotable vaporizer bypass flap (20) is adjusted. A temperature mixture flap (26) and the vaporizer bypass flap are mechanically connected with each other, where pivoting movements of the temperature mixture flap and the vaporizer bypass flap are positively coupled. A rotatable stored cam (36) is formed with a curve groove (38). An independent claim is also included for a method for carrying out temperature regulation in an inner space of a motor car.