Electric Flap Drive With Slip Sensing for Ice-Resistant Opening
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Solution Overview
Problem
Existing electric flap drives for charging or refueling flaps on motor vehicles require external buttons, which pose manufacturing challenges and are prone to ice buildup, necessitating larger motors and increased costs to handle ice-related issues.
Innovation Solution
An electric flap drive with a frictionally coupled coupling arrangement and sensor system that detects actuation through the flap itself, allowing for internal operation and minimizing ice-related issues by using a compact electric motor and self-locking gear mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an external button is provided for operating the charging flap, then the flap can be opened and closed electrically, but the button is accessible on the exterior of the vehicle body which results in considerable manufacturing effort and poses challenges regarding sealing
Solution Approach 1:
The operating button is removed from the exterior of the vehicle body and its function is extracted to the interior side. The button is now provided in the interior trim panel area, allowing electrical operation of the charging flap while eliminating the manufacturing and sealing challenges associated with exterior buttons.
Solution Approach 2:
The bulkhead serves as an intermediary structure that separates the interior and exterior sides. The electric flap drive and button are located on the interior side behind the bulkhead, while the charging port extends through the bulkhead to the exterior. This intermediary structure allows electrical operation without requiring exterior buttons.
2Ease of operation
If an external button is provided for operating the charging flap, then the flap can be opened and closed electrically, but it poses challenges regarding sealing
Solution Approach 1:
The operating button is extracted from the exterior sealing surface and relocated to the interior side behind the bulkhead. This eliminates the sealing challenges associated with providing an accessible button on the exterior of the vehicle body while maintaining electrical operation capability.
Solution Approach 2:
The bulkhead acts as an intermediary that provides a sealed barrier between the interior and exterior. By locating the button and electric flap drive behind the bulkhead on the interior side, the sealing integrity of the vehicle body is maintained while still enabling electrical flap operation.
3Ease of manufacture
If the flap is operated from inside the vehicle via an internal button, then manufacturing complexity is reduced, but it is generally preferable for the flap to be operated from the outside
Solution Approach 1:
The charging flap system is designed to accept actuation from multiple sources. The control arrangement can receive actuation signals from either an interior button (for reduced manufacturing complexity) or exterior actuation means (for operational convenience). This multi-functionality allows the system to adapt to different operating scenarios.
4Reliability
If a larger electric motor is used to handle ice buildup on the flap, then ice-related issues can be addressed, but the motor size and cost increase
Solution Approach 1:
The coupling arrangement is designed with a basic position where the input and output elements are frictionally coupled, creating preliminary engagement that prevents slippage under normal operating conditions including ice buildup. This preliminary anti-action eliminates the need for oversized motors to handle ice-related issues.
Solution Approach 2:
The patent replaces the need for large mechanical motors with a sensor arrangement that detects slippage and a control arrangement that responds to detected slippage. This substitution of mechanical force with sensing and control systems allows compact motors to handle ice-related issues effectively.
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
Enables internal operation of flaps without external buttons, reduces manufacturing complexity, and prevents ice-related failures while using a cost-effective and compact motor design.
Implementation Method 1
a coupling arrangement comprising an input element connected to the drive shaft and an output element connected to the output shaft, which are frictionally coupled in a basic position
Data Source
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AI summary
The invention relates to an electric flap drive (20), in particular for a tailboard or tank flap (10) of a motor vehicle (K), comprising: an electric motor (30) which has a drive shaft (32); an output shaft (46) which can be coupled to a flap (10); a drive gear assembly (34) which establishes a transmission between the drive shaft (32) and the output shaft (46); a clutch assembly (40) which has an input member (42) connected to the drive shaft (32) and an output member (44) connected to the output shaft (46), which members are frictionally coupled in a basic position (G); and a sensor arrangement (52) configured to detect slip of the clutch assembly (40) caused by an actuating movement (B1, B2) of the flap (10).