Variable Intake Valve Mounting for Lower NVH and Joint Damage
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Solution Overview
Problem
Conventional variable intake systems for vehicles face issues such as cracks or damage at the joint of the variable valve and air cleaner, hitting noise due to surface contact, and delayed valve opening in high-output engines, which affect noise, vibration, and harshness (NVH) performance.
Innovation Solution
A variable intake system with a revised mounting structure for the variable valve, where the valve is installed on a mounting aperture with projections and seats, and a sealing member with a 'V'-shaped section to maintain air tightness and reduce noise, along with magnets to ensure consistent valve opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the variable valve is fixed to the air cleaner using rivets or bolts before assembling the cover part, then the variable valve can be securely installed, but cracks or damage may occur at the joint during ultrasonic vibration welding
Solution Approach 1:
The mounting structure is divided into separate components: the air cleaner body with a mounting aperture, and the variable valve housing with coupling protrusions. This segmentation allows the variable valve to be mounted after the air cleaner body is formed, avoiding the conflict between rivet/bolt fixation and ultrasonic welding of the air cleaner body itself.
Solution Approach 2:
The mounting aperture and coupling protrusions are pre-formed during the injection molding of the air cleaner body, before assembly. This preliminary action eliminates the need for post-assembly fastening operations that could damage the joint during welding, as the mounting features are already integrated into the body structure.
2Ease of manufacture
If the variable valve is mounted using a conventional separable-type air cleaner structure, then the valve can be installed in the body part, but the hitting noise occurs due to surface contact between the valve and air cleaner
Solution Approach 1:
A sealing member is introduced as an intermediary element between the variable valve housing and the air cleaner body. This sealing member not only prevents air leakage but also acts as a noise-damping layer that reduces hitting noise during valve operation, while maintaining the ease of assembly provided by the coupling protrusion structure.
3Device complexity
If the variable valve is installed in a drawer-type air cleaner with ultrasonic vibration welding, then the air cleaner structure is simplified, but the valve mounting becomes difficult without open access to the body part interior
Solution Approach 1:
The mounting approach transitions from internal installation (requiring open access to the body part interior) to external mounting through the mounting aperture. The coupling protrusions extend from the housing through the aperture, allowing the variable valve to be secured from the outside after the air cleaner body is fully assembled via ultrasonic welding.
4Device complexity
If the valve opening time is not controlled, then the valve structure is simpler, but the valve opening is delayed in high-output engines affecting performance
Solution Approach 1:
A stopper mechanism is implemented that provides feedback control for valve opening timing. The stopper prevents the coupling protrusion from fully engaging the mounting aperture until the variable valve reaches a predetermined opening position, ensuring consistent and timely valve opening in high-output engine conditions while maintaining a relatively simple overall structure.
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 solution improves the robustness and durability of the variable valve, reduces hitting noise, and maintains consistent valve opening time, enhancing NVH performance by addressing the issues of joint damage and noise discharge.
Implementation Method 1
a sealing member with a 'V'-shaped section to maintain air tightness
Implementation Method 2
along with magnets to ensure consistent valve opening
Implementation Method 3
a variable valve to vary the amount of intake air according to engine operating conditions
Data Source
AI summary
A variable intake system for a vehicle is provided and includes an air cleaner that filters air via a filter and supplies the air to an engine. A main duct is connected to the air cleaner to supply the air, and a variable valve has a housing that is coupled and mounted to a mounting aperture of a mounting part disposed on a front end of the filter of the air cleaner. An internal passage of the housing is opened by suction pressure of the engine in the mounting part to suction external air. A projection formed on the housing of the variable valve is inserted into a projection seat formed in the mounting part, so that the variable valve is secured to the mounting part.