Valve Unit Coupling for Thermal Misalignment Compensation
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Solution Overview
Problem
Valve units in motor vehicles experience increased wear and inefficient power transmission due to thermal expansion, leading to reduced service life and higher power consumption, as existing coupling designs are costly and introduce undesirable forces and torques.
Innovation Solution
The coupling design features shaped elements on the intermediate piece that move within recesses, allowing for radial and axial relative movement to compensate for shaft misalignment, reducing thermal loads and production costs by using metal or plastic components, and incorporating spacers to minimize heat conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coupling with spacers and shaped elements on all three components is used, then shaft misalignment can be compensated, but production costs increase due to additional bending processes on all three components
Solution Approach 1:
The invention extracts the spacers and shaped elements from two of the three coupling components (transmission-side and flap-side) and concentrates them solely on the intermediate piece. This reduces the number of components requiring additional bending processes from three to one, significantly lowering production costs while maintaining the ability to compensate for shaft misalignment through the intermediate piece's geometry
Solution Approach 2:
The invention merges the functions of spacers and shaped elements into a single component - the intermediate piece. By combining these alignment-compensating features in one location, the patent simplifies the overall coupling structure and reduces manufacturing complexity while preserving the essential function of accommodating thermal expansion and shaft misalignment
2Adaptability or versatility
If a resilient coupling element with torsion spring is used, then shaft misalignment can be accommodated, but wear increases due to inability to maintain precise shaft alignment
Solution Approach 1:
The invention implements a dynamic geometric solution where the intermediate piece's recesses and shaped elements can shift positions relative to each other to accommodate thermal expansion and shaft misalignment. This dynamic adjustment capability maintains precise shaft alignment during operation, preventing wear while adapting to changing thermal conditions
Solution Approach 2:
The invention changes the geometric parameters of the coupling interface through the intermediate piece's recesses and shaped elements. By allowing these parameters to vary within defined ranges, the system can compensate for thermal expansion and maintain proper shaft alignment without the wear-inducing effects of resilient elements
3Ease of manufacture
If traditional coupling design is used, then production is simpler, but undesirable forces and torques are introduced into the transmission and electric motor due to shaft misalignment
Solution Approach 1:
The intermediate piece serves as a mediator between the transmission-side and flap-side coupling components. It absorbs and compensates for shaft misalignment through its geometric design, preventing the transmission of undesirable forces and torques to the electric motor and transmission while maintaining a relatively simple production process
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 minimizes wear and power consumption by compensating for thermal-induced misalignment, reducing undesirable forces and torques, and lowering production costs through efficient material use and assembly.
Implementation Method 1
Due to the high temperatures in the engine compartment or in the valve unit, thermally induced expansion occurs, so that the shafts of the valve unit are no longer precisely aligned with one another.
Data Source
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AI summary
The invention relates to a valve unit, comprising a housing (1), a flap (2), which is rotatably arranged in the housing (1) and which is connected to a flap shaft (3) supported in the housing (1), an electric motor (4) for driving the flap shaft (3), and a transmission (5), which is arranged between the electric motor (4) and the flap shaft (3). A coupling (7), which consists of a flap-side component (10), an intermediate piece (9), and a transmission-side component (8) is arranged between the flap shaft (3) and a shaft (11) of the transmission (5). At least one of the three coupling parts (8, 9, 10) has at least two first holes (12) of the same radial orientation. Furthermore, at least two second holes (13) are arranged, which are oriented perpendicular to the first holes (12). Molded elements (14, 15) of an adjacent component (8, 9, 10) of the coupling (7) engage in the holes (12, 13) and the holes (12, 13) have a greater extension with respect to the radial orientation of the holes than the molded elements (14, 15) that engage in the holes.