Flex > Case Studies > Achieving Cost-Effective Fuel Efficiency with Smart Airflow Controls

Achieving Cost-Effective Fuel Efficiency with Smart Airflow Controls

Technology Category

Robots - Autonomous Guided Vehicles (AGV)
Sensors - Environmental Sensors

Applicable Industries

Automotive

Applicable Functions

Product Research & Development

Use Cases

Onsite Human Safety Management
Vehicle Performance Monitoring

Services

System Integration

About The Customer

The customer in this case study is an automaker seeking to improve the fuel efficiency of its vehicles. The customer is aware of the increasing demand for fuel-efficient vehicles due to government regulations and the preferences of environmentally conscious consumers. The customer is also conscious of the challenges associated with the implementation of new technologies, such as active grille shutters, particularly in terms of safety and durability. The customer is committed to introducing this technology in a safe, reliable, and affordable manner, and is willing to collaborate with experts in the field to achieve this goal.

The Challenge

The automotive industry is under increasing pressure to create more fuel-efficient vehicles due to government regulations and environmentally conscious consumers. One automaker sought to improve its fuel efficiency by exploring the emerging trend of active grille shutters. These shutters, integrated into the vehicle’s front intake grille, alter the flow of air to the engine, promoting cooling when open and fuel-sparing aerodynamics when closed. However, active grille shutters are a relatively new technique in automotive design and carry challenges, particularly in safety and durability. The vendor must ensure that a grille won’t get stuck in ways that would affect vehicle performance or overheat the engine.

The Solution

The automaker partnered with the Flex Sketch-to-ScaleTM ecosystem to introduce the active grille shutter design in a safe, reliable, and affordable format. Flex used its Mirror Controls International (Flex MCi) subsidiary, which specializes in advanced actuation technology for the active grille shutters. By working with Flex and Flex MCi from the beginning of the project, the customer created a simple, highly integrated solution with fewer complex parts. Flex MCi introduced two unique features to its line of actuators to address safety and security concerns. The first, Smart Control, controls multiple actuators using a single centralized intelligence system, removing the need for a separate printed circuit board assembly in each actuator. The second feature made fail-safe operation a fundamental part of the actuator’s design, defaulting the shutter to ‘off’ mode if the system loses power or its control signal, thereby eliminating the risk of an overheated engine.

Operational Impact

The implementation of the active grille shutter system not only helped the automaker achieve its primary fuel efficiency goals but also brought additional benefits. The more controlled intake of air led to lower noise from the motor, and it also reduced the level of wind noise in the cabin, creating a more pleasant driving experience. The system also hit safety targets that are critical in a highly regulated manufacturing sector, thereby avoiding the potential costs of product recalls. The collaboration with Flex and Flex MCi from the beginning of the project allowed the automaker to create a simple, highly integrated solution with fewer complex parts, enhancing the reliability of the system.

Quantitative Benefit

Achieved primary fuel efficiency goals cost-effectively by reducing the drag effect from unnecessary air intake.
Avoided potential costs of product recalls in a highly regulated manufacturing sector.
Created a simpler, more cost-effective active grille shutter system with fewer parts that could fail.