Intake Module Control Shaft Mounting Alignment
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Solution Overview
Problem
The production of intake modules for internal combustion engines faces challenges in achieving cost-effectiveness and reliable mounting of control shafts due to manufacturing tolerances and distortion of plastic housings, which can impair the functional reliability of the control shaft and the assembly process.
Innovation Solution
The use of multiple bearing brackets with position blocks that interact with complementary guide contours in the bearing mounts for optimal alignment and low-friction bearing, and the division of bearing brackets into separate parts for improved alignment and reduced radial compression, along with a sealing groove system for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the housing is injection-moulded from plastic, then production cost is reduced and manufacturing efficiency is improved, but the housing warps due to manufacturing process, which impairs the low-friction mounting of the control shaft and functional reliability
Solution Approach 1:
The bearing bracket is divided into a first bearing part and a second bearing part that can be assembled separately. The first bearing part is inserted into the housing through an insertion opening, and the second bearing part is subsequently attached to complete the bearing bracket assembly. This segmentation allows the control shaft to be mounted before the housing is fully assembled, avoiding the problem of housing warping affecting mounting precision while maintaining the benefits of injection-moulded plastic production.
2Adaptability or versatility
If the control shaft is retrofitted into the housing after manufacturing, then assembly flexibility is improved, but housing distortion results in relatively large manufacturing tolerances that make it difficult to assemble the control shaft in a functionally reliable manner
Solution Approach 1:
The control shaft is pre-mounted into the first bearing part before the housing is fully assembled. The first bearing part is inserted into the housing through an insertion opening, and the control shaft is already in place. This preliminary action ensures that the control shaft is positioned with high precision before the housing is closed, avoiding the problems associated with retrofitting after housing distortion occurs during manufacturing.
3Device complexity
If a single bearing bracket is used for mounting the control shaft, then device complexity is reduced, but alignment precision and functional reliability are impaired due to housing warping
Solution Approach 1:
The bearing bracket is segmented into a first bearing part and a second bearing part. The first bearing part contains the control shaft and is inserted into the housing first, while the second bearing part is attached subsequently to complete the bearing bracket. This segmentation maintains relatively simple overall structure while achieving high alignment precision by allowing the control shaft to be mounted before housing distortion affects the final assembly.
Data Source
Figure 1
Figure 2
Figure 3~7
AI summary
The invention relates to an intake module (7) of a fresh air system (5) for an internal combustion engine (1), comprising a housing (14) that has an inlet opening (16) for fresh air and a flange section (19) with a plurality of outlet openings (17) for fresh air, and comprising a control device (20) for controlling a cross-section of at least one of said outlet openings (17) through which flow can pass, said control device (20) having at least one control shaft (21) and, for each outlet opening (17), at least one control valve (22) arranged in a rotationally-fixed manner on said control shaft (21), the control shaft (21) being mounted on the housing (14) by means of at least one bearing bracket (23) such that it can rotate about a rotational axis (24), said housing (14) comprising at least one bearing receiving portion (25) which receives the respective bearing bracket (23) and has an insertion opening (27) on a connection side (26) of the flange section (19), each bearing bracket (23) being inserted in an insertion direction (28) through the respective insertion opening (27) and into the associated bearing receiving portion (25). Improved control device functionality is achieved when the bearing bracket (23) comprises two outer surfaces (29) which face away from one another with respect to a transverse direction (30) and each of which comprises at least one positioning block (31) projecting therefrom, said bearing receiving portion (25) comprising, for each positioning block (31), a guiding contour (33) for the purpose of aligning the bearing bracket (23) in a longitudinal direction (34) and in the transverse direction (30).