Vehicle Air Conditioner Rack Gear Door Actuation
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Solution Overview
Problem
Conventional vehicle air conditioners face issues with increased component count and manufacturing costs due to the need for two actuators to operate two temperature-adjusting doors, which also restricts design freedom and increases the risk of misassembly and gear damage.
Innovation Solution
The design incorporates shafts with misassembly-preventing features, such as protrusions and concave grooves, and a rack gear with stopper parts to prevent misassembly and gear damage, allowing a single actuator to operate two sliding doors while enhancing assemblability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If two actuators are disposed to operate two temperature-adjusting doors, then the doors can be operated independently, but the number of components is increased and manufacturing costs rise
Solution Approach 1:
The patent combines two separate actuators into a single actuator that operates both temperature-adjusting doors simultaneously. The actuator includes a single motor that drives a gear mechanism which is connected to both doors, allowing one actuator to control the opening and closing of multiple doors in the air conditioner housing.
2Device complexity
If one actuator is used to operate two doors through a rack gear, then the number of components is reduced, but the degree of design freedom in mounting the actuator is deteriorated
Solution Approach 1:
The patent introduces a rotating shaft as an intermediate transmission element that adds a rotational dimension to the actuator mechanism. This shaft can be mounted at various positions and angles within the housing, providing flexibility in actuator placement while still driving both doors through gear connections, thus restoring design freedom in mounting configurations.
3Reliability
If the temperature-adjusting doors are located at extreme positions, then the cooling or heating effect is maximized, but the doors may be damaged since the rack gear moves continuously
Solution Approach 1:
The patent incorporates stopper members that are positioned in advance at specific locations within the housing to prevent the doors from moving beyond certain limits. These stoppers engage with the gear mechanism before the doors reach extreme positions, automatically stopping the motion to prevent damage to the doors or the rack gear while still allowing the doors to reach positions that provide effective cooling or heating.
4Ease of manufacture
If the doors are assembled without misassembly preventing structures, then the assembly process is simpler, but the possibility of misassembly gets higher
Solution Approach 1:
The patent employs asymmetric gear tooth configurations and corresponding gear grooves on the doors that only fit together in the correct orientation. The gear mechanism includes shaped engagement surfaces that prevent incorrect assembly, ensuring that the doors can only be properly assembled in the intended configuration, thereby eliminating misassembly possibilities while maintaining manufacturing simplicity.
Data Source
AI summary
The present invention relates to an air conditioner for a vehicle, which can prevent misassembly of doors and prevent damage of gears when one rack gear operates two sliding doors and increase the degree of mounting freedom of actuating means. The air conditioner for a vehicle, which includes an air-conditioning case having a heat exchanger, and a door disposed inside the air-conditioning case and sliding to adjust the degree of opening of an air passageway, includes: shafts having a first gear part geared with gear teeth formed on the door. One or more misassembly preventing parts are formed on the shafts and the first gear part.