Integrated Intake Pipe Flange Design for Straddle-Type Vehicle Assembly
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Solution Overview
Problem
The existing intake systems of saddle-riding or straddle-type vehicles face challenges in reducing the number of components, simplifying the auxiliary flow conduit construction, and enhancing assembly ease while preventing increases in the size of the pipe member connecting the throttle body and engine, which leads to difficulties in tool access and sealing performance.
Innovation Solution
The system employs a pipe member with a front flange attached to the cylinder and a rear flange attached to the throttle body, featuring a groove for intake air supply, and strategically positioned engagement members to ensure non-overlapping tool access paths, allowing for a compact design and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a connection pipe made from rubber and a band are used to connect the throttle body and cylinder, then the system can be assembled, but the number of components increases and construction of auxiliary flow conduit becomes difficult
Solution Approach 1:
The patent merges the connection pipe and auxiliary flow conduit into a single integrated pipe member structure. The pipe member includes both the connection function (with flanges for bolting) and the auxiliary flow conduit (groove) as unified components, eliminating the need for separate rubber connection pipes and bands, thereby reducing component count while maintaining assembly feasibility
Solution Approach 2:
The pipe member is designed to perform multiple functions simultaneously: it serves as both the connection conduit for intake air and the auxiliary flow conduit. The groove formed on the pipe member's outer peripheral surface provides auxiliary airflow while the flanges provide connection functionality, making the single pipe member a multi-functional component that replaces multiple separate parts
2Device complexity
If flanges are provided on both ends of the pipe member to connect throttle body and cylinder, then the number of components is reduced, but the rear flange overlaps the tool access path to the first engagement member, making assembly difficult
Solution Approach 1:
The patent resolves the assembly conflict by transitioning from a two-dimensional projection view to a three-dimensional spatial arrangement. The rear flange is positioned such that while it overlaps the first engagement member in plan view (2D), it does not overlap when viewed from the axial direction (3D). This dimensional perspective change allows both flanges and engagement members to coexist without interfering with tool access paths during assembly
3Ease of operation
If the front flange is made larger to prevent overlap with the rear flange, then assembly ease is improved, but the pipe member size increases
Solution Approach 1:
The patent avoids increasing flange size by utilizing three-dimensional spatial arrangement instead of enlarging two-dimensional flange dimensions. The flanges maintain compact sizes while achieving non-overlapping tool access paths through strategic positioning in 3D space, specifically by ensuring the rear flange does not overlap the first engagement member when viewed from the axial direction, thereby preventing interference with tool access without requiring larger flange dimensions
Data Source
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AI summary
A pipe member includes a front flange and a rear flange. The front flange is attached to a cylinder. The rear flange is attached to a throttle body. A first engagement member engages together the cylinder and the front flange. In a plan view of a vehicle, at least a portion of a throttle body is overlapped a crank case. The throttle body includes a connection portion connected to the rear flange. At least one of the connection portion and the rear flange includes a groove or channel for conducting intake air. In a side view of the vehicle, the rear flange overlaps a prolongation or extrapolation of the first engagement member extending in the axial direction of the first engagement member. As seen along the axial direction of the first engagement member, the rear flange does not overlap the first engagement member.