Toggle Lever Linkage for Asynchronous Air Flap Control
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Solution Overview
Problem
Existing air flap apparatuses for motor vehicles are complex and costly to manufacture and assemble, with known designs using shifting drums, cam plates, or Bowden cables, which suffer from precision loss over time and increased complexity.
Innovation Solution
An air flap apparatus utilizing a toggle lever linkage with two pivotably connected toggle levers and a motion drive system, allowing asynchronous displacement of air flaps between blocking and passthrough states with a simpler design, where the toggle lever linkage is mounted to change transmission ratios and positions to achieve precise asynchronous motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a shifting drum with control grooves is used to drive air flap arrangements asynchronously, then the asynchronous displacement of air flaps is achieved, but the manufacturing and assembly complexity increases
Solution Approach 1:
The shifting drum is segmented into a first control element and a second control element that can be independently actuated. This allows each air flap arrangement to be controlled separately, achieving asynchronous displacement while simplifying the overall structure by eliminating the need for complex grooves and pegs.
Solution Approach 2:
The control elements are designed to be dynamically adjustable, allowing the first and second air flap arrangements to be displaced asynchronously. The motion coupling enables independent positioning of each control element, providing dynamic control capability without the complexity of a traditional shifting drum.
2Ease of operation
If a cam plate is used as a motion coupling for asynchronous displacement, then the asynchronous motion is achieved, but the manufacturing and assembly complexity increases
Solution Approach 1:
The complex cam plate mechanism is extracted and replaced with simpler control elements. The essential function of asynchronous motion control is retained by using independently actuated control elements that can be manufactured and assembled more easily than a cam plate.
3Ease of manufacture
If Bowden cables are used to couple air flap arrangements, then the motion is transmitted, but precision is lost over time due to stretching
Solution Approach 1:
The Bowden cable mechanical system is replaced with a direct rigid linkage system. The control elements are rigidly connected to the air flap arrangements, eliminating the flexible cable that stretches over time. This substitution maintains manufacturing simplicity while significantly improving long-term precision.
4Device complexity
If a toggle lever linkage is used for motion coupling, then the asynchronous displacement is achieved with reduced complexity, but the transmission ratio must be precisely controlled
Solution Approach 1:
The transmission ratio is controlled by adjusting geometric parameters of the toggle lever linkage, specifically the distances between pivot points. By changing these parameters, the desired asynchronous motion characteristics are achieved without increasing overall system complexity.
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
The solution enables reliable asynchronous displacement of air flaps with reduced manufacturing and assembly complexity, maintaining precision and maximizing displacement travel while minimizing unnecessary motion and force, thus improving the air flow management system's efficiency.
Implementation Method 1
the motion coupling the first and the second air flap arrangement to the motion drive system in such a way that the first and the second air flap arrangement are drivable by the motion drive system asynchronously
Data Source
AI summary
An air flap apparatus for a motor vehicle, encompassing:a frame having an air passthrough opening;a first air flap arrangement and a second air flap arrangement respectively encompassing at least one displaceable first and second air flap;a common motion drive system for displacing the first and the second air flap arrangement;a motion coupling for coupling both the first and the second air flap arrangement to the motion drive system,the first air flap arrangement and the second air flap arrangement being respectively displaceable between a blocking position having a greater degree of coverage of the air passthrough opening and a passthrough position having a lesser degree of coverage of the air passthrough opening;the motion coupling the first and the second air flap arrangement to the motion drive system in such a way that the first and the second air flap arrangement are drivable by the motion drive system asynchronously for a displacement motion, the motion coupling encompasses a toggle lever linkage having a first and having a second toggle lever that are connected to one another, pivotably around a toggle joint axis, to form a toggle joint; the first toggle lever being motion-transferringly coupled to the first air flap arrangement; and the second toggle lever being motion-transferringly coupled to the second air flap arrangement; and the motion drive system being motion-transferringly coupled to the first and/or to the second toggle lever.