Modular Active Rear Diffuser Assembly for Cross-Platform Adaptation
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Solution Overview
Problem
Current aero devices for vehicles require unique designs and tooling for each vehicle, limiting adaptability and increasing costs due to the inability to easily modify or scale components for different vehicle configurations.
Innovation Solution
A modular and scalable active rear diffuser assembly that includes brackets, rails, actuators, and carriers, allowing for adjustable positioning and extension of the rear diffuser components to fit various vehicle designs, with a cover that can be made active while the bottom and top portions remain static.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current aero devices use unique designs for each vehicle, then aerodynamic performance is optimized for specific vehicles, but adaptability and manufacturing cost are reduced
Solution Approach 1:
The rear diffuser assembly is divided into multiple modular components including a first module with a first cover and a second module with a second cover. Each module can be independently designed, manufactured, and positioned. This segmentation allows the same basic module design to be adapted to different vehicle configurations by varying the number, size, and positioning of modules, thereby achieving both aerodynamic optimization and adaptability across multiple vehicle models.
Solution Approach 2:
The patent creates a universal module design that can serve multiple vehicle types and configurations. The standardized module with standardized mounting brackets and positioning mechanisms can be universally applied across different vehicle models. This multi-functionality allows a single module design to fulfill aerodynamic requirements for various vehicles without requiring unique custom designs for each application.
2Reliability
If current aero devices use unique designs for each vehicle, then aerodynamic performance is optimized for specific vehicles, but manufacturing cost and tooling requirements increase
Solution Approach 1:
By segmenting the rear diffuser into standardized modules, the manufacturing process is simplified. Each module can be manufactured using the same tooling and production lines, reducing the need for expensive custom tooling for each vehicle model. The modular approach allows for economies of scale in manufacturing while maintaining aerodynamic performance through proper module selection and configuration.
Solution Approach 2:
The universal module design enables a single manufacturing process and tooling setup to produce components for multiple vehicle models. This eliminates the need for separate manufacturing lines and tooling for each vehicle-specific design, thereby reducing manufacturing costs and complexity while maintaining the ability to achieve optimized aerodynamic performance through standardized module deployment.
3Reliability
If the entire rear fascia is made active, then aerodynamic control is maximized, but device complexity and cost increase
Solution Approach 1:
Instead of making the entire rear fascia active, the patent applies active diffuser modules only to specific local regions where aerodynamic control is most beneficial. The modules can be strategically positioned at the bottom, top, or sides of the rear fascia based on the specific vehicle's aerodynamic requirements. This localized approach maintains effective aerodynamic control while reducing overall system complexity compared to a fully active fascia design.
Solution Approach 2:
The patent implements a selectively active design where only certain portions of the rear diffuser are made movable through actuators, while other portions remain static. This dynamic approach allows aerodynamic control to be applied only where needed, reducing the complexity of having all components active while maintaining effective aerodynamic management through intelligent positioning of the active modules.
Data Source
AI summary
An active rear diffuser for a rear portion of a vehicle. The rear diffuser assembly is formed from a set of components that are uniform across all vehicle platforms, with some of the components being scalable and allowing them to be adjusted to an appropriate length without any retooling.