ACTIVE APPARATUS HAVING A DIRECT DRIVE FOR MODIFYING AERODYNAMIC PROPERTIES OF A VEHICLE

Abstract

An active apparatus for modifying aerodynamic properties of a vehicle, encompassing: an apparatus frame; an air flap mounted pivotably on the apparatus frame; and an electric motor for bringing about a pivoting motion of the air flap, the electric motor being embodied as a direct drive for the air flap.

Claims

1-12. (canceled)

13. An active apparatus for modifying aerodynamic properties of a vehicle, encompassing: an apparatus frame; an air flap mounted pivotably on the apparatus frame; and an electric motor for bringing about a pivoting motion of the air flap, wherein the electric motor is embodied as a direct drive for the air flap.

14. The active apparatus according to claim 13, wherein the electric motor is configured to perform mechanical work in the form of a rotary motion around a motor rotation axis; and the electric motor is arranged on the apparatus frame in such a way that the motor rotation axis is embodied collinearly with a pivot axis of the air flap.

15. The active apparatus according to claim 14, wherein the pivot axis of the air flap is defined by a shaft portion of the air flap; and the electric motor encompasses a bearing for the shaft portion.

16. The active apparatus according to claim 15, wherein a connection, configured for transferring the rotary motion, between a rotor of the electric motor and the air flap is embodied using an injection-molding process.

17. The active apparatus according to claim 16, wherein the electric motor encompasses an inner rotation portion and an outer rotation portion that are provided rotatably relative to one another, one portion from among the inner rotation portion and the outer rotation portion encompassing or constituting the rotor of the electric motor, and the other portion from among the inner rotation portion and the outer rotation portion encompassing or constituting a stator of the electric motor; the inner rotation portion encompassing an opening; and an injection-molding material abutting against an inner wall of the opening.

18. The active apparatus according to claim 17, wherein a wall of the inner rotation portion which faces toward the outer rotation portion is coated with the injection-molding material (401) or with a plastic.

19. The active apparatus according to claim 17, wherein the outer rotation portion is embedded in an injection-molding material for mounting in the apparatus frame or in the air flap, and/or is injection-applied onto the apparatus frame or on the air flap with the injection-molding material or is mounted by overmolding with the injection-molding material.

20. The active apparatus according to claim 19, wherein a wall of the outer rotation portion which faces toward the inner rotation portion is coated with the injection-molding material or with a plastic.

21. The active apparatus according to claim 14, wherein a connection, configured for transferring the rotary motion, between a rotor of the electric motor and the air flap is embodied using an injection-molding process.

22. The active apparatus according to claim 2l, wherein the electric motor encompasses an inner rotation portion and an outer rotation portion that are provided rotatably relative to one another, one portion from among the inner rotation portion and the outer rotation portion encompassing or constituting the rotor of the electric motor, and the other portion from among the inner rotation portion and the outer rotation portion encompassing or constituting a stator of the electric motor; the inner rotation portion encompassing an opening; and an injection-molding material abutting against an inner wall of the opening.

23. The active apparatus according to claim 22, wherein a wall of the inner rotation portion which faces toward the outer rotation portion is coated with the injection-molding material (40l) or with a plastic.

24. The active apparatus according to claim 22, wherein the outer rotation portion is embedded in an injection-molding material for mounting in the apparatus frame or in the air flap, and/or is injection-applied onto the apparatus frame or on the air flap with the injection-molding material or is mounted by overmolding with the injection-molding material.

25. The active apparatus according to claim 24, wherein a wall of the outer rotation portion which faces toward the inner rotation portion is coated with the injection-molding material or with a plastic.

26. The active apparatus according to claim 13, wherein the apparatus encompasses at least one of a sensor and a rotary encoder for determining an angular position of the air flap around a pivot axis.

27. The active apparatus according to claim 26, wherein the at least one of the sensor and the rotary encoder are configured to transfer measured data detected by them, in wireless fashion, to at least one of a communication module of the apparatus, a control apparatus of the apparatus, a regulation apparatus of the apparatus and a vehicle evaluation unit, which are respectively configured to receive those measured data.

28. The active apparatus according to claim 27, further encompassing at least one of an energy harvesting apparatus and a receiving apparatus for receiving wirelessly transferred energy, for supplying energy to at least one of the electric motor, the sensor, the rotary encoder, the control apparatus and the regulation apparatus.

29. The active apparatus according to claim 13, further encompassing at least one of an energy harvesting apparatus and a receiving apparatus for receiving wirelessly transferred energy, for supplying energy to at least one of the electric motor, a sensor, a rotary encoder, a control apparatus and a regulation apparatus.

30. The active apparatus according to claim 13, wherein the apparatus is configured to transfer data representing an angular position of the air flap, using a vehicle data bus, to a vehicle evaluation unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail and illustrated in the accompanying drawings which forms a part hereof and wherein:

[0035] FIG. 1 is a view of an embodiment of the apparatus according to the present invention, having two drive air flaps and associated further air flaps, in the opened position;

[0036] FIG. 2 is a view of the embodiment of FIG. 1 with the two drive air flaps and the associated further air flaps, in the closed position;

[0037] FIG. 3 shows a portion of a view from above (in a Z direction) of the embodiment of FIG. 1;

[0038] FIG. 4 shows a portion of an A-A section from FIG. 3;

[0039] FIG. 5 shows a further air flap of the embodiment of FIG. 1;

[0040] FIG. 6 shows an optional embodiment of a further air flap of the embodiment of FIG. 1;

[0041] FIG. 7 shows a drive air flap of the embodiment of FIG. 1; and

[0042] FIGS. 8 and 9 show optional embodiments of a drive air flap of the embodiment of FIG. 1.

[0043] In order to increase the clarity of the Figures, reference characters are not repeated in some Figures.

[0044] It is expressly noted that the Figures for the present Application are not accurately to scale, nor are they accurate depictions in terms of a relative motion of moving elements. The Figures serve merely to illustrate the principle of the present invention, and are correspondingly schematic in nature.

DESCRIPTION OF PREFERRED EMBODIMENTS

[0045] Referring now to the drawings wherein the showings are for the purpose of illustrating preferred and alternative embodiments of the invention only and not for the purpose of limiting the same, FIGS. 1 and 2 show an embodiment according to the present invention of an apparatus, embodied as an air flap apparatus 20, for modifying aerodynamic properties of a vehicle in which the apparatus is installed. FIG. 1 shows a state of air flap apparatus 20 in which air flaps 26la to 26le and 26ra to 26re are in the opened position, and FIG. 2 shows a state of air flap apparatus 20 in which air flaps 26la to 26le; 26ra, 26re are in a closed position. Air flap apparatus 20 encompasses an apparatus frame 22 that is arranged preferably in stationary fashion with respect to a chassis portion or frame portion of the vehicle. Air flap apparatus 20 can be part of a radiator grill of the vehicle which is arranged, in particular at the front in a forward direction, on an outer side of the vehicle impinged upon by the flow of an air blast. Formation of a flatter flow impingement surface in the closed position causes a change in the air resistance of the vehicle as compared with the state in which the air flaps are in the opened position.

[0046] Apparatus frame 22 comprises a flowthrough opening 24 that encompasses, preferably is constituted by, two flowthrough sub-openings 24l and 24r and an intermediate region 24z located between flowthrough sub-openings 24l and 24r. Actuators, sensors, and the like can be arranged in intermediate region 24z; in particular, this intermediate region 24z is usually covered by a body portion of the vehicle which carries a vehicle emblem.

[0047] Because the configuration of apparatus 22 is embodied substantially mirror-symmetrically with respect to a plane of symmetry M that passes perpendicularly through the drawing plane of FIGS. 1 and 2, the description hereinafter is limited to the left passthrough sub-opening 24l and to air flaps 26la to 26le arranged therein and the elements and parts of apparatus 20 interacting therewith. The corresponding reflected right-hand elements are labeled with the index “r” so that, for instance, air flaps 26ra to 26re that are arranged in mirror-image fashion with respect to air flaps 26la to 26le in terms of plane M are provided in flowthrough sub-opening 24r. The description of the left side of apparatus 20 is to be applied correspondingly to the right-hand flowthrough sub-opening 24r and to air flaps 26ra to 26re arranged therein and the elements and parts of apparatus 20 interacting therewith, unless otherwise indicated by the description. Reference characters of elements, parts, portions, or geometric representations such as rotation axes, which correspond to one another in the context of air flaps 26la to 26le or of the mounting thereof, have the same value, for instance the reference character of rotation axis Dl discussed below, but are not equipped with a serial index from a to e or b to e, and only one element, portion, or geometric representation is described in detail; that description is also to be applied to the other elements, portions, or geometric representations having the same value of the reference character but a different serial index.

[0048] Looking in a direction that is orthogonal to the drawing plane of FIGS. 1 and 2 that passes through the respective passthrough sub-opening 24l, a plurality of air flaps 26la to 26le are positioned on apparatus frame 22 rotatably on rotation axes Dla to Dle. Air flap 26la shown in FIG. 7 is embodied as a drive air flap, and air flaps 26lb to 26le each constitute preferably identically embodied further air flaps as shown in FIG. 5. Drive air flap 26la is connected via a drive rod 28l to the associated further air flaps 26lb to 26le for motion together. An electric motor 30l embodied as a direct drive is provided between apparatus frame 22 and drive air flap 26la in order to bring about a pivoting motion of drive air flap 26la. Electric motor 30l, depicted particularly well in FIGS. 3 and 4, is preferably a torque motor whose rotation axis coincides collinearly with rotation axis Dla of drive air flap 26la. Rotation axis Dla of drive air flap 26la is defined in particular by a central line of collinear and mutually oppositely located shaft portions 32la, 34la of drive air flap 26la. Shaft portion 34la is preferably mounted rotatably in a plain bearing 36la embodied in apparatus frame 22, while a rotor 38l of electric motor 30l, embodying an inner rotation portion of electric motor 30l, is anchored nonrotatably in shaft portion 32la by overmolding with injection-molding material 40l; in particular, an outer surface 42l, facing toward a stator to be described later, of a wall of rotor 38l is overmolded with injection-molding material 401 in order to protect rotor 38l from corrosion, and thus constitutes a protective layer. A layer of this kind can also be provided on end face 44l of shaft portion 32la in order to protect rotor 38l from corrosion. A first axial passthrough opening 46l, which is completely filled with injection-molding material 40l and extends along the motor rotation axis, coinciding with rotation axis Dla, of electric motor 30l, is preferably provided in rotor 38l. Two transverse passthrough openings 48l, 50l, whose cavities transition into the cavity of axial passthrough opening 46l and are likewise completely filled with injection-molding material 40l and which proceed, in the exemplifying embodiment, perpendicularly to rotation axis Dla, also extend through rotor 38l. Particularly strong anchoring of rotor 38l to drive air flap 26la is produced by the resulting material bridge between each of transverse passthrough openings 48l, 50l and axial passthrough opening 46l. Injection-molding material 40l abuts in particular against the respective inner walls of transverse passthrough openings 48l, 50l and of axial passthrough opening 46l.

[0049] Electric motor 30l further encompasses a stator 52l, which surrounds rotor 38l and constitutes an outer rotation portion of electric motor 30l. Rotor 38l preferably encompasses a permanent-magnet arrangement, and stator 52l preferably encompasses an electromagnet arrangement for driving electric motor 30l. In addition, by way of a suitable arrangement of permanent magnets and/or electromagnets of electric motor 301 in the inner rotation portion and outer rotation portion, a magnetic bearing can be provided between inner rotation portion and outer rotation portion, which bearing is also a bearing of shaft portion 32la and braces against a housing of electric motor 30l via the outer rotation portion. If a so-called “housingless” electric motor is used, the apparatus frame is to be regarded as a housing of the electric motor. Alternatively, electric motor 30l can encompass a plain bearing that is likewise braced via the outer rotation portion and also supports shaft portion 32la.

[0050] Stator 52l is overmolded with injection-molding material 54 of apparatus frame 22 and thereby arranged nonrotatably thereon. Stator 52l can also be coated with injection-molding material 54 for corrosion protection on its surface 56l, facing toward rotor 38l, of its wall. A coating of this kind can likewise be provided for corrosion protection on axial end surfaces 58l, 60l of stator 52l. A Hall sensor, e.g. a Hall sensor having a plurality of physically separated measurement fields (e.g. quadrants), for determining an angular position of the permanent-magnet arrangement of the rotor, and thus of the rotor itself, relative to the stator, can be provided in stator 52l. Alternatively and/or additionally, a voltage produced in the windings of the electromagnets of the stator by the motion of the permanent-magnet arrangement of the rotor, in particular as a result of a back magnetomotive force (BMMF) or back electromotive force (BMEF), or a current produced therein, can be detected and can be used to determine the position of the permanent-magnet arrangement of the rotor and thus of the rotor itself. Particularly preferably, electric motor 30l is embodied as a servomotor, so that separate detection of the position of the rotor is not necessary. Because rotor 52l is connected nonrotatably to apparatus frame 22 and rotor 38l is connected nonrotatably to drive air flap 26la, in all these variants an angular position of the drive air flap relative to apparatus frame 22 is thus detected.

[0051] Further air flaps 26lb to 26le are preferably embodied, mounted on apparatus frame 22, and equipped with sensors, identically to one another. Air flap 26lb is mounted pivotably around its rotation axis Dlb on shaft portions 62la and 64la in associated counterpart bearings 66lb and 68lb in apparatus frame 22. A magnet arrangement 70la, having a north pole N and a south pole S and connected nonrotatably to shaft portion 62la, is preferably provided on that shaft portion, so that the angular position of magnet arrangement 70la relative to apparatus frame 22, and thus the angular position of air flap 26lb relative to apparatus frame 22, can be detected by means of a Hall sensor 72lb, e.g. a Hall sensor having four quadrants, arranged in stationary fashion with respect to apparatus frame 22. The position of the magnet arrangements of further air flaps 26c to 26e, and thus the angular position of those individual air flaps relative to apparatus frame 22, can correspondingly be detected by way of Hall sensors (not shown) that are associated with the respective individual air flaps and are arranged in stationary fashion with respect to apparatus frame 22. Note that in order to maintain clarity, the Hall sensors have not been depicted in FIGS. 1 and 2.

[0052] Drive air flap 26la comprises at one end of its air flap blade 74la a mandrel 76la which extends parallel to rotation axis Dla of drive air flap 26la and which engages into drive rod 28l and is mounted rotatably in drive rod 28l in a bearing. Further air flap 26lb, which is embodied identically to further air flaps 26lc to 26le, furthermore likewise comprises a mandrel 76lb which extends parallel to rotation axis Dlb of further air flap 26lb and which likewise engages into drive rod 28l and is mounted rotatably in drive rod 28l in a bearing. The mandrels of further air flaps 26lc to 26le engage similarly into similar bearings in drive rod 28l, so that a pivoting of drive air flap 26la likewise results in a corresponding pivoting of all further air flaps 26lb to 26le. Drive air flap 26la and/or further air flaps 26lc are preferably embodied, using an injection-molding process, in such a way that air flap blade 74la, shaft portions 32la, 34la, and mandrel 76la are embodied continuously, preferably integrally. The same applies correspondingly to air flap blade 74lb, to shaft portions 62lb, 64lb, and to mandrel 76lb.

[0053] Electric motor 30l is preferably embodied with a power receiving part 78 of a wireless power transfer apparatus of apparatus 20. The wireless power transfer apparatus encompasses a power transmitting part (not illustrated) that is arranged on the vehicle. The wireless power transfer apparatus is furthermore configured to permit a data transfer in both directions between power receiving part 78 and the power transmitting part. The power transmitting part communicates via a transceiver with a data bus, e.g. a CAN bus, of the vehicle, which in turn communicates with a vehicle evaluation unit, e.g. an ECU, of the vehicle. Electric motor 30l is preferably embodied with a control unit and regulation unit which is connected in terms of data technology, in wire-based or wireless fashion, to power receiving part 78 in order to receive control instructions of the vehicle via the data bus and the wireless power transfer apparatus. Power receiving part 78 is an embodiment of a communication module of apparatus 20.

[0054] Each of the Hall sensors, or sensors for detecting the respective angular position, which is associated with drive air flap 26la and with further air flaps 26lb to 26le is preferably also configured to communicate wirelessly with power receiving part 78 and to transfer to the vehicle, via the wireless power transfer apparatus and the data bus, the respective angular position of the associated drive air flap 26la and/or of each of further air flaps 26lb to 26le, so that those angular positions are available, for example, to an OBD1/OBD2 diagnostic system.

[0055] Power receiving part 78 can also furnish the aforesaid functions for electric motor 30r and for the Hall sensors, or sensors for detecting the respective angular position, associated with air flaps 26ra to 26re.

[0056] FIG. 6 shows an optional embodiment of the further air flap of apparatus 20, only the differences with respect to further air flaps 26lb to 26le being discussed below. Reference characters incremented by 100 are used for the elements, sub-portions, etc. of this optional embodiment which correspond to those of the embodiment described above, reference being made, with regard to those elements, sub-portions, etc., to the description of the corresponding elements of the embodiment described above. The further reference characters of apparatus 20, as well as axis designations, remain those of the embodiment described above.

[0057] The same is correspondingly the case for the optional embodiment of the drive air flap shown in FIG. 8, reference characters incremented by 200 being used for the elements, sub-portions, etc. of this optional embodiment which correspond to those of the embodiment described above. In the optional embodiment of the drive air flap shown in FIG. 9, reference characters incremented by 300 are analogously used for the elements, sub-portions, etc. corresponding to those of the embodiment described above.

[0058] Further air flap 126lb, preferably identical in design to all further air flaps, differs from further air flap 26lb in that instead of the magnet arrangement for detection by way of Hall sensor 72lb in air flap 126lb, an RFID position sensor 182lb is provided which is configured to determine the angular position of further air flap 126lb relative to apparatus frame 22 and to transfer it wirelessly to power receiving part 78, which can have the function of an RFID reading device. When a further air flap 126lb of this kind is provided, provision of the associated Hall sensor on apparatus frame 22 can be dispensed with.

[0059] The embodiment of drive air flap 226la shown in FIG. 8 is provided for use in an apparatus 20 in which the outer rotation portion encompasses an arrangement of permanent magnets, and the inner rotation portion encompasses an arrangement of electromagnets.

[0060] A power receiving part 278 is correspondingly provided on an air flap blade 274la of drive air flap 226la in order to supply energy to the arrangements of electromagnets in the inner rotation portion.

[0061] The embodiment of drive air flap 326la shown in FIG. 9 differs from drive air flap 226la in that an RFID position sensor 384, which is preferably embodied as an active RFID sensor and is preferably supplied with energy from power receiving part 378, is provided for determining the angular position of drive air flap 326la relative to apparatus frame 22. RFID position sensor 384 is preferably configured to transfer the angular position wirelessly to power receiving part 78, which can have the function of an RFID reading device.

[0062] While considerable emphasis has been placed on the preferred embodiments of the invention illustrated and described herein, it will be appreciated that other embodiments, and equivalences thereof, can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. Furthermore, the embodiments described above can be combined to form yet other embodiments of the invention of this application. Accordingly, it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.