EGR Valve Assembly With Sliding Valve Body for Tolerance Control
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Solution Overview
Problem
Existing EGR-valve systems require tight tolerances and complex assembly processes, making them time-consuming and costly to manufacture and adjust.
Innovation Solution
A gas flow control valve system with a slidingly arranged second valve body on a shaft, allowing for adjustable tolerances and eliminating the need for precise fitting and re-adjustment, utilizing a spring and bushing mechanism to ensure proper positioning and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If both valve bodies are fixed to the same shaft, then tight tolerances are required to ensure that both valve bodies fit their respective valve seats, but the assembly becomes complex and time-consuming
Solution Approach 1:
The valve device is segmented into two independent valve body assemblies: a first valve body fixedly coupled to the shaft, and a second valve body slidingly arranged on the shaft. This segmentation allows each valve body to be independently positioned and adjusted relative to its corresponding valve seat, eliminating the need for both valve bodies to be precisely fixed to the same shaft. The sliding arrangement of the second valve body provides independent adjustment capability, simplifying the overall assembly process while maintaining tight tolerances for each individual valve seat fit.
2Manufacturing precision
If both valve bodies are fixed to the same shaft, then tight tolerances are required, but the assembly process requires welding and testing outside the valve
Solution Approach 1:
By segmenting the valve body arrangements (one fixed, one sliding), the invention enables simpler assembly procedures. The sliding second valve body can be adjusted and positioned without requiring welding operations outside the valve housing. This eliminates the need for complex external testing and readjustment procedures, as each valve body can be independently positioned to achieve proper fit with its corresponding valve seat during the assembly process.
Solution Approach 2:
The second valve body is designed with sliding capability on the shaft, providing dynamic adjustment capability during assembly. This dynamic arrangement allows the second valve body to be easily positioned and adjusted to achieve proper alignment with its valve seat, eliminating the need for rigid fixed coupling and subsequent external testing and readjustment procedures required in static designs.
3Manufacturing precision
If tight tolerances are required for valve body fitting, then manufacturing precision is improved, but manufacturing time and cost increase
Solution Approach 1:
The segmented valve body design allows each valve body to be independently manufactured and positioned, enabling parallel assembly processes. The sliding arrangement of the second valve body provides built-in adjustment capability that eliminates time-consuming external testing and readjustment procedures. This independent positioning capability maintains tight tolerances for each valve seat fit while significantly reducing overall assembly time and improving manufacturing productivity.
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 system simplifies assembly, reduces manufacturing costs, and enhances robustness by allowing for larger tolerances and easier adjustment, while maintaining precise control over gas flow recirculation in vehicle exhaust systems.
Implementation Method 1
a spring is arranged between the first valve body and the second valve body, the spring being adapted to exert a force on the second side of the second valve body to press the second valve body towards the retainer
Data Source
Figure 1~2
Figure 3~4
AI summary
Valve (1) for controlling gas flow, comprising - at least one gas inlet (3); - at least one first gas outlet (5) and one second gas outlet (7) ; - a valve device (9) adapted for blocking or unblocking the first gas outlet (5) and/or the second gas outlet (7); the valve device (9) comprising - an axially movable shaft (11); - a first valve body (13) adapted for blocking or unblocking the first gas outlet (5) by interacting with a first valve seat (17) of the first gas outlet (5), the first valve body (13) being fixedly coupled to the shaft (11); - a second valve body (15) adapted for blocking or unblocking the second gas outlet (7) by interacting with a second valve seat (19) of the second gas outlet (7), the second valve body (15) being slidingly arranged on the shaft (11).