Adjustment Element for Overrun Air Recirculation Valve
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Solution Overview
Problem
Existing divert-air valves face issues with noise during operation, limited thermal resistance, and poor leak tightness, especially when adapting to different turbocharger pressure conditions, leading to increased production costs and potential sealing problems.
Innovation Solution
The adjustment element comprises a control body with a first and second hollow body, where the second hollow body is sealingly fastened to the first, allowing for a tilting movement without deformation, and an elastomer is used for noise damping, enabling the use of thermally resistant materials like sheet metal and ensuring leak-tight closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic control body with form-locking elements is used, then the valve can be produced cost-effectively, but the thermal resistance is limited and leak tightness is insufficient
Solution Approach 1:
The control body is constructed as a composite structure combining a plastic housing with a metal insert. The plastic portion provides cost-effective manufacturing and form-locking functionality, while the metal insert embedded in the control body delivers the required thermal resistance and enhanced leak tightness. This composite approach resolves the contradiction by integrating materials with complementary properties.
2Reliability
If the control body shape is adapted for different cross sections, then sealing performance improves, but production costs increase due to multiple designs
Solution Approach 1:
The control body is segmented into modular components: a standardized plastic housing portion and a configurable metal insert portion. The metal insert can be adapted to different cross-sectional shapes and sealing requirements while the main housing remains standardized. This segmentation allows customization for sealing performance without requiring complete redesign of the entire control body, thus controlling production costs.
3Manufacturing precision
If the control body is rigidly connected to the actuation element, then actuation precision improves, but noise during operation increases
Solution Approach 1:
A damping element, specifically an elastomer component, is introduced as an intermediary between the control body and the actuation element. This elastomer serves dual functions: it maintains the precise positional relationship required for accurate actuation while simultaneously dampening vibrations and reducing operational noise. The elastomer acts as a mediator that reconciles the contradiction between precision and noise.
4Temperature
If thermally resistant materials like sheet metal are used, then thermal resistance improves, but production cost increases
Solution Approach 1:
Instead of manufacturing the entire control body from thermally resistant sheet metal, the invention applies thermal resistance locally through a metal insert positioned only in the regions requiring heat resistance. The remaining portions of the control body use cost-effective plastic material. This local quality approach provides the necessary thermal resistance while minimizing production costs by limiting expensive material usage to where it is most needed.
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 configuration results in a divert-air valve that is cost-effective, thermally resistant, and provides high leak tightness with reduced noise and quick actuation times, capable of adapting to various cross sections without shape changes.
Implementation Method 1
an elastomer is used for noise damping
Implementation Method 2
a radially outer annular plate which is configured to be sealingly fastened in an encircling manner axially to the annular plate of the first hollow body
Data Source
AI summary
An adjustment element for a divert-air valve. The adjustment element includes an actuation element which moves translatorily, and a control body which moves with the actuation element. The control body includes a first hollow body and a second hollow body. The first hollow body includes an outer surface which is circumferentially closed so as to define an interior, a first axial end, and an annular plate which extends radially inward from the first axial end. The second hollow body includes a radially outer annular plate which is sealingly fastened in an encircling manner axially to the annular plate of the first hollow body, and a radially inner region in which an outer surface extends in a direction of the actuation element in the interior of the first hollow body.