Brushless Air Valve with Non-Contact Sensor for Engine Reliability
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Solution Overview
Problem
Existing air management systems for engines face reliability issues due to the short life expectancy of brush-type permanent magnet motors and contact wiper throttle position sensors, and they often have complex, cumbersome designs that are difficult to integrate into various applications.
Innovation Solution
The development of an air valve using a brushless direct current (BLDC) motor assembly with a non-contact throttle position sensor and an integrated electronic valve controller, capable of communicating via PWM and CAN signals, which includes a torsion spring for biasing the throttle plate and a compact design to manage high pressures and provide precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brush type permanent magnet motors are used for air flow management, then the motor can provide sufficient torque and speed control, but the reliability is reduced due to short life expectancy
Solution Approach 1:
The patent replaces the brush type permanent magnet motor with a brushless direct drive (BLDC) motor. This substitution eliminates the mechanical brush-commutator interface that causes wear and reliability issues, thereby extending motor life expectancy and improving reliability while maintaining the required torque and speed control capabilities.
Solution Approach 2:
The patent removes the brush component from the motor design entirely. By extracting the problematic brush element, the system eliminates the source of mechanical wear and reliability failures, resulting in a longer-lasting motor suitable for extended engine operation.
2Reliability
If contact wiper throttle position sensors are used, then the sensor can provide feedback for engine control, but the reliability is reduced due to short life expectancy and wear
Solution Approach 1:
The patent replaces the contact wiper type throttle position sensor with a non-contact sensor (such as a magnetic or optical sensor). This substitution eliminates the mechanical contact and wear issues inherent in wiper-based sensors, thereby extending sensor life expectancy and improving reliability while maintaining accurate throttle position feedback.
3Measurement precision
If complex air valve designs are used to achieve precise control, then the control accuracy is improved, but the device becomes difficult to fit into applications due to size and weight
Solution Approach 1:
The patent integrates the motor, gear reduction mechanism, and sensor into a single compact air valve assembly. By merging these components into one unified structure, the design achieves precise control functionality while minimizing overall size and weight, making it suitable for various engine applications including marine and industrial engines.
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
The solution provides a robust, reliable, and compact air valve with a long lifespan, capable of managing high pressures and achieving precise control, with a response time of less than 125 ms and a valve position resolution of less than 1 angular degree, suitable for heavy-duty compression ignition engines and new engine technologies.
Implementation Method 1
a brushless direct current motor assembly in connection via a pinion with the driven gear
Implementation Method 2
the throttle position sensor comprises at least one non-contact type sensor
Implementation Method 3
a torsion spring, wherein a gear reduction is achieved through a single stage gear set
Data Source
AI summary
An air valve and its method of use including an air valve housing; a throttle plate disposed on a throttle shaft; a driven gear attached on the throttle shaft; a brushless direct current motor assembly in connection via a pinion with the driven gear; an integrated electronic valve controller including digital signal processing on a circuit board; and a throttle position sensor on the circuit board, wherein the throttle position sensor includes at least one non-contact type sensor. In a preferred embodiment, the air valve includes an inlet port and an outlet port connected to an engine via an air intake manifold, such that re-circulated exhaust gas is introduced into the air intake manifold.