Intake Air Control System with Flapper Valves
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Solution Overview
Problem
Conventional intake manifold systems for internal combustion engines are inefficient at low engine speeds due to fixed cross-sectional areas, leading to reduced air-fuel mixture velocity and increased fuel consumption, and existing designs that adjust velocity by reducing cross-sectional area compromise structure and operation with significant torque and reduced effectiveness.
Innovation Solution
A control system with variable area intake runners actuated by flapper valves using a four-bar link design driven by a hypoid gear-set and DC electric motor, allowing for adjustment based on engine speed and load conditions to optimize air-fuel mixture velocity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a single pivot is used to rotate the valve plate to decrease cross-sectional area at low RPMs, then air velocity increases, but significant torque is applied to the pivot compromising structure and operation
Solution Approach 1:
The invention divides the single pivot into multiple pivots (first pivot and second pivot) that support the valve plate at different locations. This segmentation distributes the torque load across multiple support points, reducing the stress on each individual pivot while maintaining the valve plate's ability to rotate and control airflow cross-section.
Solution Approach 2:
The invention adds a spatial dimension to the pivot support system by positioning pivots at different locations along the valve plate rather than using a single centralized pivot. This dimensional distribution of support points creates a more stable structural configuration that better handles the rotational forces during valve operation.
2Speed
If the valve plate tip does not extend closer to the combustion chamber in the extended position, then the mounting flange can be smaller, but the effectiveness of increasing air fuel velocity in the combustion chamber is reduced
Solution Approach 1:
The invention makes the valve plate position dynamic through rotation about multiple pivots, allowing the valve plate tip to extend closer to the combustion chamber when needed. This dynamic positioning capability enables the system to optimize airflow velocity at different operating conditions without being constrained by a fixed mounting flange size, as the valve can assume different angular positions to achieve optimal performance.
3Productivity
If a flat valve plate with single pivot is used to adjust cross-sectional area, then air velocity can be increased at low RPMs, but the system complexity and structural integrity are compromised
Solution Approach 1:
By segmenting the pivot support into multiple locations on the valve plate, the invention reduces the complexity burden on each individual pivot while maintaining the overall functionality. This segmentation approach allows the system to achieve the desired airflow control without requiring an overly complex single-pivot mechanism with excessive support structures.
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 system increases air-fuel mixture velocity at low engine speeds, enhancing engine efficiency and power output while maintaining structural integrity and effectiveness by positioning flapper valves closer to the combustion chamber, reducing air leakage, and minimizing torque loads.
Implementation Method 1
a DC electric motor, the control system controls the DC electric motor to actuate the system to either engage or retract the flapper valves
Implementation Method 2
Each flapper valve is coupled to a drive link that is driven by a hypoid gear-set. The hypoid gear-set is in turn driven by a worm drive gear-set
Implementation Method 3
a four-bar link design driven by a hypoid gear-set and DC electric motor
Implementation Method 4
the valve plate is actuated to rotate about the single pivot to decrease the cross-sectional area of the intake runner... to increase the velocity of the air-fuel mixture
Implementation Method 5
Each flapper valve is coupled to a drive link that is driven by a hypoid gear-set... a four-bar link design
Data Source
AI summary
An intake control system for a multi-cylinder combustion engine with control valves positioned within intake passageways that can vary the cross-sectional area of the intake runners to increase air intake velocity at low engine speeds. The control system includes an inner frame that can be inserted into a lower manifold after manufacture. The inner frame includes a plurality of flapper valves that are actuated by a four-bar link design, which is driven by a hypoid gear-set. The control system controls an internal DC electric motor that actuates a worm-drive gear-set, which in turn drives the hypoid gear-set to either engage or retract the flapper valves within the intake passageways.