Throttle Actuator Plastic Cover Electric Machine Integration
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Solution Overview
Problem
Current throttle designs for motor vehicles are costly due to the need for metal housing and machining to accommodate the electric machine, and they occupy excessive space due to the chamber's location.
Innovation Solution
A throttle design with a plastic cover that houses the electric machine, eliminating the need for a metal chamber and machining, featuring a torque transfer apparatus with gears and washers for vibration reduction, and thermally conductive adhesive for heat dissipation, while maintaining the electric machine's functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the electric machine is installed in the metal throttle housing, then the housing provides structural support and protection, but material costs and processing costs increase significantly
Solution Approach 1:
The throttle device is divided into two functional modules: the metal housing containing only the throttle valve mechanism, and the separate plastic cover containing the electric machine. This segmentation allows each part to be optimized for its specific function and manufacturing process, reducing overall costs.
Solution Approach 2:
The electric machine is extracted from the metal housing and placed in a separate plastic cover. This extraction eliminates the need to machine expensive metal housing to accommodate the electric machine, significantly reducing material and processing costs while maintaining structural integrity.
2Quantity of substance
If the chamber for the electric machine is located on one side of the throttle throat, then the electric machine can be accommodated, but the transverse dimension of the throttle increases
Solution Approach 1:
The electric machine is positioned above the throttle throat in the vertical dimension rather than extending the transverse dimension horizontally. The plastic cover is designed to enclose the electric machine in a compact vertical arrangement, reducing the overall transverse width of the throttle assembly.
3Strength
If the housing is made of metal alloy, then strength and durability are improved, but material cost and processing cost increase
Solution Approach 1:
Different materials are used for different functional requirements: metal housing for the throttle valve mechanism requiring strength and durability, and plastic cover for the electric machine where cost-effectiveness and ease of manufacturing are priorities. This local quality differentiation optimizes both performance and cost.
Solution Approach 2:
The throttle device uses a composite construction combining metal and plastic materials. The metal housing provides structural strength for the throttle mechanism, while the plastic cover provides cost-effective enclosure for the electric machine, creating a hybrid structure that balances performance and cost.
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 design reduces material and processing costs, minimizes space requirements, and effectively manages vibrations and heat dissipation, enhancing the throttle's operational efficiency and cost-effectiveness.
Implementation Method 1
a wave washer and a flat washer are provided between the top and a top wall of the chamber; the wave washer presses against the top end of the electric machine
Implementation Method 2
thermally conductive adhesive is provided between the housing and the cover
Data Source
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AI summary
The present device relates to a throttle, comprising: a housing, having a throttle throat; a cover mated with the housing, the material of the cover being plastic; an electric machine; a torque transfer apparatus meshed with an output end of the electric machine; a throttle shaft connected in a fixed manner to the torque transfer apparatus, the throttle shaft passing through the throttle throat, and being supported by being inserted into a first mounting hole and a second mounting hole in the throttle housing; a butterfly valve mounted on the throttle shaft and located inside the throttle throat; the electric machine being located in the cover. Since the electric machine is located in the cover, there is no need for a chamber for accommodating the electric machine to be provided in the housing, so material costs are reduced, and there is no need for the chamber and screw holes for fixing the electric machine to be formed in the cover by machining, so processing costs are reduced.