Load Limiter for Controllable Air Inlet
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing designs for controllable air intake in motor vehicles lack a simple and reliable mechanism for opening the air inlet and do not provide protection against drive-side malfunctions, particularly in scenarios where excessive torque is applied or closing elements are blocked.
Innovation Solution
A load limiter system featuring a driver on the output side that is pivoted by a spring means to open the closing elements automatically, allowing manual separation of drivers and incorporating a torsion spring for torque limitation, ensuring the air inlet opens when excessive torque is detected, and disengages to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the driver on the output side is manually separated to open the air inlet, then the air inlet opens reliably, but the device complexity increases due to requiring separate manual means
Solution Approach 1:
The spring means automatically pivots the driver on the output side to the open position when the drivers are separated, eliminating the need for additional manual opening mechanisms. The system serves itself by using the separation action to trigger the spring-driven opening motion.
Solution Approach 2:
The driver on the output side is separated into functionally independent parts: the driver body that transmits torque and the closing elements that control air intake. This segmentation allows the driver to be pivoted independently by the spring means while maintaining the torque transmission function through the form-fitting contours.
2Reliability
If the drivers are designed with form-fitting contours for torque transmission, then the torque transmission is reliable up to specified limits, but the device complexity increases due to precision contour design
Solution Approach 1:
The form-fitting contours are designed to dynamically respond to torque levels. Under normal operation, the contours maintain positive contact for reliable torque transmission. When excessive torque is applied, the contours automatically disengage, providing dynamic protection without requiring complex sensors or control systems.
Solution Approach 2:
The potential harmful effect of excessive torque is converted into a useful disengagement mechanism. The form-fitting contours are designed so that excessive torque naturally causes the drivers to separate, which then triggers the spring means to open the air inlet for protection. The harmful torque overload becomes the trigger for the safety mechanism.
3Extent of automation
If the spring means is prestressed to automatically open the air inlet upon separation, then the opening response is automatic and fast, but the manufacturing precision requirements increase
Solution Approach 1:
The spring means is prestressed during assembly to prepare the driver on the output side for automatic opening. This preliminary action stores potential energy in the spring, which is then released when the drivers separate, providing fast automatic opening response without requiring complex control systems during operation.
4Reliability
If the driver on the output side is pivoted in the opening direction by spring means, then protection against drive-side malfunctions is provided, but the loss of energy increases due to spring prestress
Solution Approach 1:
The spring means operates in a periodic cycle: it is compressed during normal operation when the drivers are engaged, storing energy, and then releases this energy when the drivers separate to open the air inlet. After opening, the spring resets to its prestressed state, ready for the next cycle. This periodic operation minimizes continuous energy loss.
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 ensures reliable and automatic opening of the air inlet while providing protection against excessive torque, ensuring optimal engine temperature control and preventing drive-side malfunctions by disengaging when torque limits are exceeded.
Implementation Method 1
A torsion spring is placed on the mandrel of the driver on the drive side and is supported with one leg each on the drivers. The torsion spring is prestressed in such a way that when the drivers are axially disengaged, the driver on the output side is rotated in the direction of opening the coupled closing elements.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The load limiter has a drive-side driver (M1) coupled to an engine of motor vehicle and an output-side driver (M2) for relaying torque from engine to closing elements of controllable air inlet. The drive-side driver and the output-side driver are configured for positive interlocking contact with each other and also for axial movement relative to one another in order to disengage the positive interlock. A torsion spring (DS) is configured to pivot the output-side driver relative to drive-side driver, during disengaged state of output-side driver.