Modular Control Valve Rotatable Actuator Housing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing control valves for motor vehicle internal combustion engines require re-adaptation and new molds for each customer with different flow channel housing geometries, leading to high manufacturing and assembly costs due to the integrated design of flow and actuator housing parts.
Innovation Solution
Decoupling the flow channel housing part from the actuator housing part allows for independent manufacturing and adaptation, with the actuator housing part being rotatable relative to the flow channel housing part, enabling easy adjustment to various vehicle conditions and installation spaces, and using modular components to reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the flow channel housing part and actuator housing part are formed as an integrated die-cast housing, then structural strength and sealing are improved, but manufacturing flexibility and adaptability to different customer requirements deteriorate
Solution Approach 1:
The housing is divided into two separate parts: the flow channel housing part and the actuator housing part. These parts can be manufactured independently using standard die-casting processes, then joined together. This segmentation allows each part to be optimized separately and enables adaptation to different customer requirements by modifying only the flow channel housing part without redesigning the entire housing.
Solution Approach 2:
The flow channel housing part and actuator housing part are joined together through threading or flange connections to form a complete housing assembly. This merging maintains the structural integrity and sealing performance of an integrated housing while preserving the manufacturing flexibility of separate components.
2Ease of operation
If the actuator housing part protrudes outside the flow line with a separate drive device, then functional requirements are met, but assembly space requirements increase
Solution Approach 1:
The drive device is integrated into the actuator housing part, which itself is integrated into the flow channel housing part. This nested arrangement allows the drive mechanism to be compactly positioned within the existing housing structure, minimizing the protrusion outside the flow line and reducing the required assembly space while maintaining full actuator functionality.
3Reliability
If a separate housing is provided for the drive device protruding from the actuator housing part, then drive protection is improved, but device complexity increases
Solution Approach 1:
The drive device housing is merged with the actuator housing part to form a single integrated component. This integration provides adequate protection for the drive device while eliminating the need for additional separate housings, thereby reducing the overall device complexity and the number of assembly steps.
Data Source
Figure 1
AI summary
Control valve (1) for mounting on a flow channel housing (10) of a motor vehicle internal combustion engine, comprising a flow channel housing part (20, 20a) having at least one flow inlet opening (21) and a flow outlet opening (22), a control element (41) arranged in the flow channel housing part (20, 20a) with which a passage between the flow inlet opening (21) and the flow outlet opening (22) can be controlled, an actuating element (42) with a longitudinal axis (200) to which the control element (41) is attached and which extends longitudinally through an opening (28, 28a) of the flow channel housing part (20, 20a), an actuator (40) by means of which the actuating element (42) can be set in motion, and an actuator housing part (30). The flow channel housing part (20) and the actuator housing part (30) are usually formed in one piece.To simplify assembly and manufacturing, it is proposed that the flow channel housing part (20) and the actuator housing part (30) are each designed separately, and that the actuator housing part (30) can be placed on the flow channel housing part (20, 20a) in at least two positions rotated about the longitudinal axis (200) relative to the flow channel housing part (20, 20a).