Engine Flap Module With Integrated Stops for Compact Flow Control
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Solution Overview
Problem
Existing flap devices for internal combustion engines require large installation space, are complex and costly due to external mechanical stop devices, and struggle with precise control and tight sealing, especially for small exhaust gas flows.
Innovation Solution
A compact flap device design featuring a limiter on the adjusting lever and a cover with stop elements on the flow channel housing, allowing for precise control and tight sealing with a reduced number of components and a space-saving arrangement, enabling easy adjustment and cost-effective manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external mechanical stop devices are used to limit flap rotation, then the flap position can be controlled, but the installation space requirement increases and device complexity increases
Solution Approach 1:
The stop elements are integrated directly into the cover component, merging the limiting function with the existing protective cover structure. This eliminates the need for separate external stop devices and reduces installation space requirements while maintaining reliable flap position control.
Solution Approach 2:
Instead of placing stop devices outside the flow channel housing, the invention inverts the arrangement by integrating the stop elements into the cover that closes the opening. This internal integration approach reduces external space requirements while achieving the same positional limiting function.
2Reliability
If external mechanical stop devices are used to limit flap rotation, then the flap position can be controlled, but the device complexity and manufacturing cost increase
Solution Approach 1:
The stop elements are merged with the cover structure, reducing the total number of components. The cover now serves dual functions: protecting the internal components and providing the mechanical stop elements for flap position control, thereby simplifying the overall device complexity.
Solution Approach 2:
The cover is designed with multi-functionality, serving both as a protective enclosure and as the source of stop elements for limiting flap rotation. This universal design eliminates the need for dedicated stop devices, reducing component count and simplifying assembly.
3Area of stationary object
If a compact design is achieved by integrating stop elements into the cover, then installation space is reduced, but the tightness of the flap sealing may be compromised
Solution Approach 1:
The stop elements are strategically positioned at specific locations on the cover where they can effectively limit flap rotation to achieve complete closure. This localized positioning ensures that the compact design does not compromise sealing tightness, as the stops are placed precisely where needed to enable full flap engagement with the sealing surface.
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to a flap device (1) for an internal combustion engine, having: a flow channel housing (2) which delimits a flow channel (20) having at least one inlet opening (21) and a first outlet opening (22); and a flap module (3) which can be inserted through an opening (24) into the flow channel housing (2) and has at least one flap shaft (30) rotatably mounted in the flow channel housing (2), a flap body (31) on the flap shaft (30) for controlling a flow cross-section of the flow channel (20), a bearing element (36) which is arranged in the opening (24) and through which the flap shaft (30) extends, and an actuation lever (33) which is connected for conjoint rotation to the flap shaft (30) at an end (37a) of the flap shaft (30) which protrudes out of the flow channel housing (2) and has a coupling member (34) for coupling to an actuating drive device (5) and/or to an actuating gear mechanism (51). According to the invention, at least one limiter (35) for limiting a rotary movement of the actuation lever (33) is arranged on the actuation lever (33), and a separate cover (4) which closes the opening (24) is arranged on the flow channel housing (2), on which cover at least one stop element (43a, 43b) which interacts functionally with the limiter (35) is arranged.