MÉTODO PARA EXAMINAR VARIAÇÕES CRÍTICAS NA FOLGA ENTRE O SENSOR E A RODA FÔNICA DE UM MOTOR DE COMBUSTÃO INTERNA

Description

1 / 8 METHOD FOR EXAMINING CRITICAL VARIATIONS IN THE CLEARANCE BETWEEN THE SENSOR AND THE PHONIC WHEEL OF AN INTERNAL COMBUSTION ENGINE Field of invention

[0001] The present invention falls within the area of ​​methods for examining dimensions of vehicle parts. More specifically, the present invention applies to a method for detecting and correcting critical variations in the clearance between a rotation sensor and a phonic wheel during stamping processes. State of the art

[0002] Fuel injection and ignition are two fundamental systems for the operation of an internal combustion engine. Fuel injection is responsible for supplying the air-fuel mixture to the engine cylinder, ensuring that it is suitable for combustion.

[0003] The ignition system has the function of generating the spark that ignites the air-fuel mixture, initiating the combustion process. In gasoline engines, this spark is generated by spark plugs, controlled by the engine's electronic management module.

[0004] Fuel injection and ignition depend on several factors such as cylinder position and crankshaft rotation speed, which work in a synchronized manner, with electronically controlled precision, to ensure efficiency, performance and reduced emissions.

[0005] The identification of the cylinder position and crankshaft rotation speed is measured by the rotation sensor, which picks up pulses from a phonic wheel or cam wheel connected to the crankshaft.

[0006] The clearance between the sensor and the reluctor wheel in an internal combustion engine is a critical factor for the accurate detection of the electrical signal generated by the sensor. This signal is a direct response to changes in the magnetic field when the teeth of the reluctor wheel pass the sensor, allowing the identification of the angular position and rotational speed of the crankshaft. This information is essential for the engine's electronic management system to accurately calculate ignition timing and fuel injection. Variations in this clearance can lead to weak or distorted signals, resulting in poor engine timing, misfires, or inefficient combustion. A method for examining these variations helps maintain optimal sensor performance, ensuring precise engine operation and minimizing fuel consumption and emissions. Petition 870250006128, dated 01 / 26 / 2025, page 10 / 32 2 / 8

[0007] In addition to affecting performance, variations in clearance can lead to mechanical problems. If the clearance becomes too small, there is a risk of physical contact between the sensor and the phonic wheel, causing wear or damage to both components. On the other hand, an excessively large clearance can cause signal loss or delay, impacting engine response time. A robust examination method helps identify and mitigate these risks during manufacturing, reducing the likelihood of costly repairs and extending the service life of internal combustion engine components.

[0008] Modern engines, including those with VVT (Variable Valve Timing) systems, rely heavily on precise sensor-trigger interactions to optimize performance under varying driving conditions. Internal combustion engines, in particular, require fine-tuning to handle different fuel mixtures effectively. A systematic method for examining critical variations in sensor-trigger clearance ensures the reliability of these advanced systems, enhancing engine adaptability and overall efficiency. This methodology supports the growing demand for cleaner and more efficient vehicles, ensuring consistent and reliable engine performance.

[0009] The main challenge in examining variations in the clearance between the sensor and the phonic wheel lies in managing the precision required to ensure reliable signal detection, accommodating manufacturing tolerances, material deformations, and thermal expansions. In the prior art, some previous techniques have already attempted to provide a solution to this problem. As an example of the prior art we have: US8698488B2.

[0010] US8698488B2 discloses an arrangement for detecting the rotational speed of a wheel or any other rotating body by means of a sensor, which is coupled by means of a magnetic field to an encoder that rotates with the rotating body.

[0011] In US8698488B2, two separate signal paths are provided with sensor elements of different sensitivity. The signal paths are designed so that one signal path is always available, which is provided with a maximum sensitivity rating so that, in the normal case, minimum encoder track defects are achieved, simultaneously with maximum air dots, while at the same time there is always an observation signal path, whose sensitivity is rated in such a way that inversion is avoided under all magnetic conditions.

[0012] US8698488B2 uses a dual-signal path approach with different sensitivities to detect rotational speed and manage variations in sensor clearance. Petition 870250006128, dated 01 / 26 / 2025, page 11 / 32 3 / 8 phonic wheel. It focuses on using magnetic field sensors and signal processing techniques to adapt to variations in air clearance.

[0013] US8698488B2 is more focused on real-time signal processing and redundancy through dual signal paths. US8698488B2 does not disclose statistical and simulation-based methodology for slack evaluation with specific predefined parameters and measurements.

[0014] Considering the state-of-the-art solutions, it is verified that these do not effectively solve the technical problem related to a method for examining critical variations in the clearance between the sensor and the phonic wheel of an internal combustion engine, thus illustrating the need for new solutions on the market. Objectives of the invention

[0015] One objective of the present invention is to examine the critical variations in the clearance between the sensor and the phonic wheel of an internal combustion engine. Brief description of the invention

[0016] The present invention discloses a method for examining critical variations in the clearance between the sensor and the phonic wheel of an internal combustion engine comprising the following steps: a) verification of the MUD (Digital Mock-Up), b) traditional approach of ASV (Analysis of Simulation of Variation), c) detection of burr formation and simulation of the stamping process, d) statistical profiling of samples, e) refinement of the ASV (Analysis of Simulation of Variation) model, f) statistical measurement of dynamic gaps, g) correlation with sensor performance and ASV (Analysis of Simulation of Variation) reports.

[0017] Step a) analyzes the entire 3D model in its nominal condition.

[0018] Step b) maintains the traditional ASV (Analysis of Variation Simulation) approach and analyzes the dimensional variations of the phonic wheel components.

[0019] Step c) detects the formation of burrs during stamping and detects springback and any risk of geometric tolerance variation when stamping the teeth of the phonic wheel.

[0020] Step d) performs statistical analyses of physical samples.

[0021] Step e) incorporates burr profile data into the refined ASV (Analysis of Variation Simulation) model and incorporates tolerance variation between the teeth of the phonic wheel. Petition 870250006128, dated 01 / 26 / 2025, page 12 / 32 4 / 8

[0022] Step f) ensures that the clearance is measured dynamically using the refined ASV (Analysis of Variation Simulation) model loaded with physical data points of burrs measured by a profilometer.

[0023] Step g) uses sensor performance data to adjust clearance measurements.

[0024] The number of data points in the ASV (Analysis of Simulation of Variation) is between 3 and 18 points.

[0025] In step d) the average deviation is between 0.19 and 0.36 mm.

[0026] The gap between the sensor and the phonic wheel is between 0.6 and 1.36 mm. Brief description of the figures

[0027] The present invention will be described in more detail after the presentation of the figures, which contain a preferred configuration. The figures show: Figure 1 illustrates a view of an internal combustion engine from a vehicle. Figure 2a illustrates a perspective view of an internal combustion engine of a vehicle with a multi-layer type phonic wheel. Figure 2b illustrates a cross-sectional view of an internal combustion engine from a vehicle with a multi-layered phonic wheel. Figure 3a illustrates a perspective view of an internal combustion engine of a vehicle with a toothed phonic wheel. Figure 3b illustrates a cross-sectional view of an internal combustion engine of a vehicle with a toothed phonic wheel. Figure 4a illustrates a perspective view of an internal combustion engine of a vehicle with a toothed wheel. Figure 4b illustrates a cross-sectional view of an internal combustion engine from a vehicle with a toothed wheel. Figure 5a illustrates a perspective view of an internal combustion engine of a vehicle with a multi-layer type phonic wheel. Figure 5b illustrates a cross-sectional view of an internal combustion engine from a vehicle with a multi-layered phonic wheel. Figure 6a illustrates a perspective view of an internal combustion engine of a vehicle with a toothed phonic wheel. Figure 6b illustrates a cross-sectional view of an internal combustion engine of a vehicle with a toothed phonic wheel. Petition 870250006128, dated 01 / 26 / 2025, page 13 / 32 5 / 8 Figure 7a illustrates a perspective view of an internal combustion engine of a vehicle with a toothed wheel. Figure 7a illustrates a cross-sectional view of an internal combustion engine from a vehicle with a toothed wheel. Figure 8 illustrates an analysis of geometric tolerance variation using finite element analysis of the stamping process. Figure 9 illustrates a phonic wheel. Figure 10 illustrates a flowchart for reading the sensor signal. Figure 11 illustrates a measurement graph of the backlash signal sensor. Figure 12 illustrates a flowchart of the method for examining critical variations in the clearance between the sensor and the phonic wheel of an internal combustion engine.

[0028] The reference elements present in the figures are: air flow 1, internal combustion engine 100, engine cover 101, phonic wheel 102, mounting point 103, sensor 104, phonic wheel 105, crankshaft 106, central valve 107 and actuator 108. Detailed description of the invention

[0029] Before the invention is described in detail, it should be understood that it is not limited to the specific component parts of the described apparatus, as such components may vary. It should also be understood that the terminology used herein is only for the purpose of describing particular embodiments and is not intended to be limiting. It should be noted that, as used in the descriptive report and appended claims, the singular forms a, an, and the include singular and / or plural referents, unless the context clearly indicates otherwise. Furthermore, it should be understood that, in the case of parameter ranges delimited by numerical values ​​being provided, the ranges are considered to include these limiting values.

[0030] The present invention discloses a method for examining critical variations in the clearance between the sensor 104 and the phonic wheel 105 of an internal combustion engine 100 comprising the following steps: a) verification of the MUD (Digital Mock-up), b) traditional approach of ASV (Analysis of Simulation of Variation), c) detection of burr formation and simulation of the stamping process, d) statistical profiling of samples, e) refinement of the ASV (Analysis of Simulation of Variation) model, f) statistical measurement of dynamic gaps, g) correlation with the performance of the sensor 104 and ASV (Analysis of Simulation of Variation) reports. Petition 870250006128, dated 01 / 26 / 2025, page 14 / 32 6 / 8

[0031] Step a) analyzes the 3D model assembly in its nominal condition. This step evaluates the designed clearance between the sensor and the phonic wheel.

[0032] The present invention details, in an integrated manner, a method for analyzing the critical clearance between the sensor 104 and the phonic wheel 105, focusing on the accuracy and performance of the internal combustion engine 100. In the context of the steps described, the analysis of the 3D model in its nominal condition (step a) is an essential basis, as it allows for the evaluation of the initial conformity of the designed dimensions and their suitability to the required specifications. This initial evaluation considers the clearance parameters necessary to ensure the optimal functionality of the system and avoid interference or failures. Furthermore, this step ensures that the digital model accurately reflects the relevant geometric and structural aspects, serving as a reference for the subsequent simulations and analyses described in the following steps, including dimensional variations, the impact of manufacturing processes, and dynamic performance.

[0033] Step b) maintains the traditional ASV (Analysis of Variation Simulation) approach and analyzes the dimensional variations of the components of the phonic wheel 105.

[0034] This analysis is crucial for evaluating the influence of such variations on the clearance between sensor 104 and phonic wheel 105, ensuring that the system's operation remains within tolerable limits. The traditional ASV (Analysis of Variation Simulation) approach uses simulations based on statistical models, such as Monte Carlo and Gaussian Profiling, and detailed geometric data, such as angular tolerance measurements of the phonic wheel teeth and dimensional variations of the edges due to burr formation, to predict dimensional behavior under operating conditions. These elements allow for design optimization and mitigation of risks of failures or performance losses caused by inconsistencies in the manufacturing or assembly process.

[0035] Step c) detects the formation of burrs during stamping and detects springback and any risk of geometric tolerance variation when stamping the teeth of the toothed phonic wheel 105.

[0036] This step includes detecting the formation of burrs, which can compromise the dimensional accuracy and functionality of the system, as well as influence the critical clearance between sensor 104 and the phonic wheel 105. Springback, a common phenomenon in metal forming processes, is also evaluated, as it can cause unwanted residual deformations in the stamped teeth of the phonic wheel 105. This analysis allows for risk prediction. Petition 870250006128, dated 01 / 26 / 2025, page 15 / 32 7 / 8 associated with variations in geometric tolerance, ensuring that the manufacturing process meets the designed specifications and minimizing performance problems and / or incompatibilities during the operation of the 100 internal combustion engine.

[0037] Step d) performs statistical analyses of physical samples.

[0038] Through this step, real data from manufactured parts are collected, allowing for a precise evaluation of the tolerance distribution and discrepancies in relation to the theoretical model. Advanced statistical tools, such as histograms, control charts, and standard deviation calculations, are employed to measure and interpret the variability of critical dimensions. These analyses provide essential information to correlate part quality with design requirements, identify potential failure causes, and validate or refine the ASV (Analysis of Variation Simulation) model, ensuring the reliability and robustness of the system in the internal combustion engine 100.

[0039] Step e) incorporates burr profile data into the refined ASV (Analysis of Variation Simulation) model and incorporates tolerance variation between the teeth of the toothed phonic wheel 105.The measured statistical values ​​are considered as input, replacing the initial input of the design, to bring the simulation closer to the physical reality.

[0040] This integration allows for a more accurate representation of the actual manufacturing and operating conditions of the toothed phonic wheel 105. Furthermore, tolerance variations between the wheel teeth are considered, which can directly influence the clearance between sensor 104 and the phonic wheel 105, as well as the accuracy of the generated signal. This step is essential for improving the reliability of the simulations, more accurately identifying the potential impacts of geometric irregularities on system performance, and allowing for more effective adjustments to manufacturing processes and design parameters to ensure optimal functionality of the internal combustion engine 100.

[0041] Step f) ensures that the clearance is measured dynamically using the refined ASV (Analysis of Variation Simulation) model loaded with physical data points of burrs measured by a profilometer.

[0042] For this purpose, the refined ASV (Analysis of Variation Simulation) model is used, which has been previously adjusted with detailed physical data on the burrs obtained through precise measurements with a profilometer. The use of this data allows simulating real operating conditions and observing changes in dynamic gaps over time, taking into account the effects of deformations, vibrations and other variations. Petition 870250006128, dated 01 / 26 / 2025, page 16 / 32 8 / 8 that can occur during the operation of the internal combustion engine 100. This approach improves the accuracy of measurements and provides a better assessment of the impact of tolerances and manufacturing defects on system performance.

[0043] Step g) uses performance data from sensor 104 to adjust clearance measurements. Tolerance values ​​previously analyzed in a tolerance simulation software (ASV) are applied to the so / bvsredo sensor to correct the readings, ensuring accuracy and reliability.

[0044] This performance data provides information on how the sensor is functioning under real operating conditions, such as variations in sensitivity, accuracy, and response to the dynamic environment of the internal combustion engine 100. By integrating this information into the measurement process, it is possible to calibrate and correct clearance measurements, taking into account the specific behaviors of the sensor 104 in different situations, such as thermal variations, vibrations, or other factors that may influence its performance. This adjustment improves the accuracy of the analysis and contributes to more rigorous clearance control, ensuring efficient and safe system operation.

[0045] The number of data points in the ASV (Analysis of Simulation of Variation) is between 3 and 18 points.

[0046] In step d) the average deviation is between 0.19 and 0.36 mm.

[0047] The gap between sensor 104 and phonic wheel 105 is between 0.6 and 1.36 mm.

[0048] It should be noted that the drawings presented are not necessarily to scale and are merely conceptual in nature. Nevertheless, it is expressly provided that all combinations of elements that perform the same function in substantially the same way to achieve the same results as the elements now claimed are within the scope of the present invention. Finally, it should be noted that the scope of protection of the present invention covers other possible variations, not being limited solely by the content of the claims alone, including possible equivalents. Petition 870250006128, dated 01 / 26 / 2025, page 17 / 32

Claims

1 / 2 Claims 1. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100) characterized by comprising the following steps: a) MUD verification; b) traditional ASV approach; c) burr formation detection and stamping process simulation; d) statistical profiling of samples; e) ASV model refinement; f) statistical measurement of dynamic gaps; g) correlation with sensor (104) performance and ASV reports.

2. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized by step a) analyzing the 3D model assembly in its nominal condition.

3. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that step b) maintains the traditional ASV approach and analyzes the dimensional variations of the components of the phonic wheel (105).

4. Method for examining critical variations in clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that step c) detects the formation of burrs during stamping and detects springback and any risk of variation in geometric tolerance when stamping the teeth of the toothed phonic wheel (105).

5. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that step d) perform statistical analyses of physical samples.

6. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that step e) incorporates burr profile data into the refined ASV model and incorporates tolerance variation between the teeth of the toothed phonic wheel (105). Petition 870250006128, dated 01 / 26 / 2025, page 18 / 32 2 / 2 7. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that step f) ensures that the clearance is measured dynamically using the refined ASV model loaded with physical data points of burrs measured by a profilometer.

8. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that step g) uses sensor (104) performance data to adjust clearance measurements.

9. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claims 1 and 3, characterized in that the number of data points on the ASV is between 3 and 18 points.

10. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claims 1 and 5, characterized in that in step d) the average deviation is between 0.19 and 0.36 mm.

11. Method for examining critical variations in the clearance between the sensor (104) and the phonic wheel (105) of an internal combustion engine (100), according to claim 1, characterized in that the clearance between the sensor (104) and the phonic wheel (105) is between 0.60 and 1.36 mm. Petition 870250006128, dated 01 / 26 / 2025, page 19 / 32

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