Throttle Valve Intake Mounting for Drop-Safe Assembly
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Solution Overview
Problem
The assembly of intake systems is time-consuming and prone to component damage, particularly with short throttle bodies, due to the risk of the throttle body falling off during installation, which can lead to damage of the throttle plate.
Innovation Solution
An intake system design featuring positioning pins that secure the throttle valve assembly to the intake manifold, ensuring proper alignment and preventing it from falling off during assembly, combined with a secure mounting mechanism using screws through aligned bores and threads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If the throttle body is made short to simplify assembly, then assembly time is reduced, but the risk of the throttle body falling off and damaging the throttle plate increases
Solution Approach 1:
The patent applies preliminary action by providing a positioning pin that is already in place on the intake manifold before the throttle body is installed. This positioning pin protrudes into the throttle body assembly area, creating a preliminary mechanical constraint that prevents the throttle body from falling off during the assembly process. The positioning pin is designed to engage with a corresponding recess in the throttle body, ensuring the throttle body remains securely held in its correct position throughout assembly, thereby eliminating the risk of damage while maintaining the short throttle body design for quick assembly
Solution Approach 2:
The positioning pin acts as an intermediary element between the intake manifold and the throttle body. It mediates the connection by providing a mechanical interface that guides and secures the throttle body during assembly. The positioning pin transfers the positioning function from the final bolted connection to an intermediate stage, allowing the throttle body to be safely installed and positioned before the final securing operation
2Reliability
If the throttle valve assembly is bolted in place immediately to prevent falling off, then component damage risk is reduced, but assembly time increases due to the multi-step tightening process
Solution Approach 1:
The positioning pin performs a preliminary securing function before the final bolting operation. By providing initial mechanical support and positioning, it allows the throttle body to be safely installed without requiring immediate application of the full multi-step tightening process. The positioning pin maintains security during the critical transition period when the throttle body is first installed but not yet fully secured
Solution Approach 2:
The fastening function is segmented into two distinct stages: the positioning pin provides initial mechanical support and positioning, while the bolts provide final secure attachment. This segmentation allows the assembly process to be divided into manageable steps, where the positioning pin handles the critical safety function of preventing falls during installation, and the bolts complete the secure attachment, thereby reducing overall assembly time while maintaining reliability
Data Source
Figure 1~2
Figure 3
AI summary
An intake system (1) having an intake pipe (2), a throttle-valve unit (6) and a clean-air pipe (8), wherein the throttle-valve unit has a first end side (28), which adjoins an inlet (4) of the intake pipe, and wherein the intake-pipe inlet (4) and the first end side (28) have interacting first contours, which clearly define an attachment position of the throttle-valve unit (6) to the intake pipe (2), characterized in that the first contours enclose at least one positioning pin (18) of the intake pipe (2), the positioning pin extending, in a first bore (12) of the throttle-valve unit (6), through a plane which is parallel to the first end side (28) and contains the centre of gravity of the throttle-valve unit.