Movable Baffle Muffler with Ball Screw Actuation
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Solution Overview
Problem
Existing muffler systems with movable baffles controlled by electromagnets cannot precisely adjust the baffle position based on engine revolutions per minute, leading to suboptimal exhaust sound control and reduced ride comfort.
Innovation Solution
A muffler system with a slidable baffle and a controller that uses a drive motor, ball screw, and transfer frame to move the baffle to a precise position within a predetermined range, based on input data such as engine RPM, temperature, and flow rate, utilizing a reinforcement learning algorithm to determine the optimal position for minimum exhaust sound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electromagnet is used to control baffle position, then control simplicity is improved, but position control precision deteriorates
Solution Approach 1:
The patent replaces the electromagnet-based mechanical control system with a motor-driven ball screw mechanism. This substitution enables continuous, precise positioning of the baffle along the longitudinal axis of the housing, transforming the binary on/off control into fine-grained positional control while maintaining operational simplicity through electronic control.
Solution Approach 2:
The patent implements dynamic baffle positioning by enabling continuous movement along the longitudinal direction of the housing. The baffle can be adjusted to any position within a predetermined range based on real-time engine operating conditions, transforming the static two-position system into a dynamic multi-position system that adapts to varying exhaust characteristics.
2Device complexity
If baffle position is controlled to only two positions, then device complexity is reduced, but exhaust sound control effectiveness deteriorates
Solution Approach 1:
The patent transforms the static two-position baffle system into a dynamic continuous-position system. The baffle can now be positioned at any location within a predetermined range along the longitudinal direction of the housing, enabling continuous adjustment of the exhaust sound frequency range control based on real-time engine operating conditions.
Solution Approach 2:
The patent changes the control parameter from binary (magnetized/not magnetized) to continuous position coordinates. By controlling the baffle's longitudinal position as a continuous variable rather than a discrete state, the system achieves fine-grained control over exhaust sound characteristics across different engine RPM ranges.
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
This configuration allows for precise control of the baffle position, maximizing noise reduction effects by varying the exhaust sound frequency range according to engine RPM, thereby improving ride comfort and exhaust sound management.
Implementation Method 1
a ball screw rotated by the drive motor; and a transfer frame which is screwed with one side of the ball screw to be slid by the rotation of the ball screw
Data Source
AI summary
A muffler having a movable baffle may include a housing where an input pipe into which exhaust gas is flowed from an engine and an output pipe through which the exhaust gas is expelled to atmosphere are disposed, a baffle which is configured to be slidable along the longitudinal direction of the housing and divides the space of the housing, baffle moving means for moving the baffle to an arbitrary position within a predetermined range along the longitudinal direction of the housing, and a controller which data for determining whether to move the baffle or not is input thereto when the engine is driven, determines whether to move the baffle or not by use of the input data and controls the baffle moving means when the baffle is determined to be moved.