Exhaust Gas Control Valve With Helical-Gear Torque Multiplication
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Solution Overview
Problem
Conventional exhaust gas control valves require space-consuming and costly gear arrangements for torque multiplication to overcome increasing forces exerted by exhaust gas, particularly on the valve body, necessitating larger components and materials.
Innovation Solution
The exhaust gas control valve employs a helical gear with a motion converter to convert rotational motion to linear motion, enhancing torque multiplication without the need for additional space-consuming components or costly materials, using a pinion gear and helical gear with a specific gear ratio and helix angle to improve contact ratio and reduce stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If conventional gear arrangements are used to provide torque multiplication, then the force exerted on the valve member can be overcome, but the device becomes space-consuming and costly
Solution Approach 1:
The patent changes the geometric parameters of the gear system by using a helical gear with a specific helix angle (5-15 degrees) and tooth profile, which improves the contact ratio and allows for higher torque multiplication within a compact space. This parameter optimization enables the valve to achieve the necessary force multiplication without requiring larger or more complex gear arrangements.
2Productivity
If larger valve bodies are used to permit higher exhaust gas flow, then the flow capacity increases, but the force exerted on the valve member increases, requiring even more torque multiplication
Solution Approach 1:
The patent optimizes the gear parameters including the helix angle (5-15 degrees), number of teeth, and tooth profile to achieve a higher contact ratio. This allows the valve body to be enlarged for increased flow capacity while the optimized gear system provides the necessary torque multiplication to handle the increased force without requiring proportional increases in actuator size or complexity.
3Power
If higher torque multiplication is required to overcome increasing exhaust gas forces, then the valve can handle higher flow rates, but the gear arrangement becomes more complex and space-consuming
Solution Approach 1:
The patent achieves higher torque multiplication by optimizing the helical gear parameters (helix angle of 5-15 degrees, improved contact ratio) rather than adding more gears or stages. This single-stage optimized gear arrangement provides the necessary power multiplication while maintaining simplicity and compactness, avoiding the complexity of multi-stage or planetary gear systems.
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 helical gear design achieves a 72% increase in lift force and allows for a larger valve body, enabling higher exhaust gas flow rates while reducing wear and packaging space, and incorporates a resilient shaft shield for enhanced durability and corrosion resistance.
Implementation Method 1
a helical gear configured to receive torque from the pinion gear. The helical gear includes a plurality of helically arranged teeth
Implementation Method 2
The helical gear improves a contact ratio between the helical gear and an adjacent gear to increase the amount of torque able to be transmitted. Thus, the helical gear permits a higher relative torque multiplication
Implementation Method 3
a motion converter configured to convert rotational motion of the helical gear to linear motion of the valve member
Data Source
AI summary
An exhaust gas control valve includes a housing having an interior wall defining a housing interior, a pinion gear coupled to the housing and configured to be rotatably driven, and a helical gear configured to receive torque from the pinion gear and including a plurality of helically arranged teeth. The exhaust gas control valve also includes a valve member disposed at least partially in the housing interior of the housing. The valve member includes a valve shaft extending along an axis and having first and second shaft ends, and a valve body coupled to the valve shaft adjacent to the second shaft end and moveable with the valve shaft along the axis between a first valve position and a second valve position. The exhaust gas control valve further includes a motion converter configured to convert rotational motion of the helical gear to linear motion of the valve member.