Throttle Body Air Flow Control Device with Segmented Gear Transmission
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Solution Overview
Problem
Existing throttle body control devices face challenges in accurate adjustment and maintenance, particularly during low-load engine conditions, due to mechanical and technological limitations in the drive mechanisms used for controlling the throttle and bypass valves, leading to inefficiencies and increased costs.
Innovation Solution
A geared control device with a pair of toothed-sector elements and a pinion system, where the toothed-sector elements are designed to provide a direct drive on the throttle valve shaft, allowing for precise rotation angle detection and enhanced operation control, while minimizing the number of components and maintenance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single electric motor with gear transmission is used to drive both throttle valve and bypass valve, then cost and bulk are reduced, but adjustment capacity and maintenance requirements worsen
Solution Approach 1:
The gear transmission is segmented into two independent pinions (first pinion for throttle valve, second pinion for bypass valve) that can be independently adjusted and maintained. This segmentation allows the system to use a single motor while maintaining ease of repair through modular gear components.
Solution Approach 2:
The gear transmission acts as an intermediary mechanism between the single electric motor and the two valves. It provides differential motion distribution, allowing the motor to control both valves through separate gear paths that can be independently maintained.
2Adaptability or versatility
If a disc drive with two distinct circumferential guiding slots and control rods is used, then both valves can be controlled, but adjustment capacity and maintenance requirements worsen
Solution Approach 1:
The control rods and circumferential guiding slots are extracted from the system and replaced with a direct gear-to-shaft connection. The pinions directly engage with the throttle valve shaft and bypass valve shaft, eliminating the intermediate rod-slot mechanism and reducing structural complexity.
Solution Approach 2:
The mechanical rod-and-slot guidance system is replaced with a gear meshing system. The toothed pinions directly transmit rotational motion to the valve shafts, providing a more compact and easier-to-maintain mechanical connection.
3Ease of manufacture
If toothed gears with continuous motion from electric motor are used, then driving is simplified, but differentiated intervention sequence on valves requires complex timing
Solution Approach 1:
The gear transmission system is designed with dynamic engagement characteristics. The first and second pinions are positioned to engage with their respective valve shafts at different rotational positions of the motor, automatically providing the required differentiated intervention sequence through the inherent geometry of the gear arrangement.
Solution Approach 2:
The gear positions are pre-configured during manufacturing to establish the correct intervention sequence. The pinions are positioned such that when the motor rotates, the valves are actuated in the required sequence without needing additional control mechanisms.
4Adaptability or versatility
If motor drive occurs through protruding elements that establish driving connection only upon reaching certain rotation angles, then differentiated valve control is achieved, but direct drive on throttle valve shaft and accurate rotation angle detection are compromised
Solution Approach 1:
The drive connection is merged directly with the valve shafts. The pinions mesh directly with the throttle valve shaft and bypass valve shaft, providing both differentiated intervention and direct drive. This eliminates the need for separate protruding elements and maintains accurate rotation angle detection capability.
Data Source
Figure 1
Figure 2~4
Figure 3A~3B
AI summary
It is disclosed a control device of a primary air flow duct and a secondary air channel within a throttle assembly for the air supply to an internal combustion engine, comprising a driving electric motor (2) and a toothed gearing transmission (5, 6, 7) for transferring the motion from said electric motor (2) to a driving shaft (A) of at least one throttle valve for the choking of said primary air flow duct and to a driving element (12, 12') of a bypass valve (18, 18') of said secondary air channel, wherein said toothed gearing transmission (5, 6, 7) is arranged to mesh with a first toothed-sector element (8) integral in rotation with said driving shaft (A) of said throttle valve of the primary air flow duct, said toothed gearing transmission (5, 6, 7) is arranged to mesh also with a second toothed-sector element (9, 9'), idle with respect to said driving shaft (A) of the throttle valve and apt to be coupled in rotation with said first toothed-sector element (8) by rigid coupling in one direction and through an elastic element (11) in the opposite direction, said second toothed-sector element (9, 9') having a driving appendix (12a, 12a') of said bypass valve (18, 18').