Cam Phaser Control Valve Piston Disc Tilting Prevention
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Solution Overview
Problem
Existing control valves for cam phasers in internal combustion engines are complex and difficult to assemble, leading to potential tilting or wedging of piston discs and increased wear, which complicates camshaft phase adjustment and requires additional space.
Innovation Solution
A control valve design featuring a cylindrical housing with a control piston device, including piston discs supported by flat support elements and a torsion spring, allowing for axial movement and reducing wear, with a compact configuration that minimizes space usage and facilitates quick camshaft adjustment. The piston discs are made from lightweight materials like aluminum, and the design includes radial seals and spacers for efficient fluid flow and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional control valves are used with piston discs in the control piston, then the cam phaser can adjust the camshaft phase, but the piston discs may tilt or wedge during operation, leading to increased wear and assembly complexity
Solution Approach 1:
The control piston is divided into multiple control pistons, each with its own piston disc and check valve. This segmentation allows each piston disc to be independently supported by flat support elements, preventing tilting and wear while maintaining functional effectiveness. The segmentation also simplifies assembly by allowing modular installation of each control piston unit.
2Adaptability or versatility
If conventional control valves with larger axial dimensions are used, then sufficient space is available for functional components, but more space is consumed in the joint arrangement with the cam phaser
Solution Approach 1:
The control piston is positioned within the housing such that it utilizes the internal space efficiently. The piston discs are arranged axially offset from each other, allowing nested positioning of multiple functional components within the compact axial space. This nesting approach maximizes the use of available space for functional components while minimizing the overall axial length of the control valve.
3Ease of operation
If conventional control valves are used, then camshaft phase adjustment can be performed, but the assembly process is complex and time-consuming
Solution Approach 1:
The control piston device is pre-assembled as a complete unit before installation into the housing. This preliminary assembly includes positioning the control piston, piston discs, check valves, and flat support elements in their correct configurations. This pre-assembly approach simplifies the final installation process, reducing assembly time while ensuring proper configuration for camshaft phase adjustment operation.
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 simple, cost-effective, and compact control valve that prevents tilting and wear, enhances response speed, and reduces material and assembly complexity, allowing for efficient camshaft phase adjustment with reduced space requirements.
Implementation Method 1
the first piston disc and the second piston disc are arranged offset from each other by a torsion spring so that a control chamber is formed between the first piston disc and the second piston disc
Implementation Method 2
control valves or hydraulic valves are being used to control a fluid flow between the cam phaser and a reservoir or tank
Data Source
AI summary
A control valve for a cam phaser of an internal combustion engine, the control valve including a cylindrical housing, including a first operating connection, a second operating connection, a supply connection, and a tank drain connection configured to drain a hydraulic fluid; a control piston device, including a control piston, a piston shaft, a first check valve, and a second check valve; wherein the control piston device is arranged in the housing and movable by an actuator in an axial direction of the housing, wherein the first check valve is configured with a first piston disc and the second check valve is configured with a second piston disc and the first piston disc and the second piston disc are arranged offset from each other by a torsion spring so that a control chamber is formed between the first piston disc and the second piston disc.