Modular Valve Interface for Actuator Pairing
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Solution Overview
Problem
The automotive industry faces challenges in developing and validating valve units for exhaust systems with cylinder deactivation technology due to the need for various valve/actuator combinations, leading to time-consuming and costly development efforts, especially for small production quantities.
Innovation Solution
A modular valve unit with a standardized interface and adapter system that allows pairing of different actuators with various valve housings of different sizes and shapes, reducing the need for extensive development and validation by using a standardized engagement portion for the interface and adaptable mounting for actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different valve/actuator combinations are developed for various applications, then the valve unit can be adapted to specific combustion engine and vehicle requirements, but the development and validation efforts become time-consuming and costly, especially for small production quantities
Solution Approach 1:
The valve unit is divided into separate modular components: a valve housing with integrated interface, and a separate actuator assembly with mounting portion. This segmentation allows independent development and validation of each component, reducing overall development time while maintaining application-specific adaptability through different interface and mounting portion configurations.
Solution Approach 2:
A standardized interface is designed with engagement portion comprising engagement legs that can universally engage with corresponding engagement orifices in the adapter. This universal interface design allows the same valve housing to work with different actuators and adapters, reducing the need for multiple specialized valve/actuator combinations while still meeting specific application requirements.
2Adaptability or versatility
If multiple valve/actuator pairings are validated for different applications, then the valve unit can meet specific requirements, but the costs become considerable compared to small production quantities
Solution Approach 1:
By segmenting the valve unit into standardized interface components and application-specific components, the patent enables separate validation of each module. This reduces the need for validating every possible valve/actuator combination, as only the standardized interface needs universal validation, while specific adaptations can be validated independently, lowering overall development costs.
Solution Approach 2:
The standardized interface with engagement legs and engagement orifices creates a universal connection system that works across different valve and actuator configurations. This universality allows a single validated interface design to serve multiple applications, eliminating the need for costly validation of each unique valve/actuator pairing while maintaining pairing flexibility.
3Ease of operation
If a standardized interface with engagement legs and engagement orifices is used, then the adapter can be easily connected to the valve housing, but the interface design becomes more complex
Solution Approach 1:
Instead of designing complex internal mechanisms for connection, the patent uses simple protruding engagement legs on one side and corresponding engagement orifices on the other side. The connection is achieved by inserting the engagement legs into the engagement orifices, reversing the traditional approach of using recesses and plugs, thereby simplifying the interface structure while maintaining ease of connection.
Solution Approach 2:
The engagement legs and engagement orifices are designed to self-align and self-connect during assembly. The geometric configuration of the engagement portion allows automatic positioning and engagement without requiring additional alignment mechanisms or complex fastening procedures, reducing interface complexity while ensuring easy connection.
Data Source
AI summary
A modular valve unit for controlling the flow rate of an intake or exhaust gas of a combustion engine through the passage of a valve, the valve unit comprising a valve having a valve housing (1) and at least one valve flap (2). The valve unit further comprises an interface (3) and an adapter (6), the interface (3) being connected to the valve housing (1) and having a support (32) and an engagement portion comprising at least two engagement legs (31) projecting from the distal end of the support (32) and being directed away from the valve housing (1). The adapter (6) has a connection plate (62) having at least two engagement orifices (61) for receiving the engagement legs (31) of the interface (3) and a mounting portion for holding an actuator (7). The at least two engagement orifices (61) of the connection plate (62) of the adapter (6) are each configured to engage the corresponding at least two engagement legs (31) of the engagement portion of the interface (3).