Resilient End Stop for Coolant Control Valve Load Limiting
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Solution Overview
Problem
Coolant control valves in internal combustion engines face end stop failure due to fatigue and excessive loads, leading to improper function and calibration issues, as rigid plastic end stops break down, causing the rotary valve to rotate past its intended position.
Innovation Solution
A coolant control valve with a resilient end stop arrangement that includes a resilient element connected to the housing, capable of compressing and collapsing under excessive loads, allowing the rotary valve to rotate past when forces exceed the resilient element's resistance, thereby preventing damage and maintaining calibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rigid plastic end stops are used to limit rotary valve rotation, then manufacturing cost and weight are reduced, but the end stops break due to fatigue and excessive loads
Solution Approach 1:
The end stop is changed from a rigid plastic component to a resilient element capable of elastic deformation. This parameter change in material properties allows the end stop to absorb excessive loads through compression and expansion, preventing breakage while maintaining the ability to limit rotary valve rotation under normal operating conditions
Solution Approach 2:
The resilient element is pre-configured with elastic properties to cushion against excessive loads before they can cause damage. When abnormal forces occur, the resilient element compresses to absorb the shock, protecting the rotary valve and housing from potential damage caused by uncontrolled rotation
2Length of moving object
If end stop thickness is reduced to maximize rotary valve travel, then valve rotation range is increased, but end stop strength and durability are further reduced
Solution Approach 1:
The end stop transitions from a rigid structure to a resilient element with elastic properties. This allows the end stop to maintain sufficient strength despite reduced thickness, as the resilient material can deform under load and return to its original position, preventing permanent damage while allowing maximum rotary valve travel
Solution Approach 2:
The end stop becomes a dynamic component that can change its effective thickness through elastic compression and expansion. During normal operation, it maintains its calibrated position to limit rotation, but under excessive loads, it compresses to allow temporary over-travel, then returns to its original position, providing both strength and maximum travel range
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 resilient end stop arrangement effectively blocks excessive loads, preventing end stop failure and maintaining proper valve operation by compressing and decompressing to align with the rotary valve, ensuring continuous calibration and operation.
Implementation Method 1
a resilient element connected to the housing... resisting, with the resilient element and with a second force, compression of the resilient element
Implementation Method 2
capable of compressing and collapsing under excessive loads... when the first force is greater than the second force, rotating the end stop past the resilient element
Data Source
AI summary
A coolant control valve for an internal combustion engine, including: a housing; a first rotary valve disposed within the housing, the first rotary valve including an axis of rotation and an end stop; and a resilient element connected to the housing. In a first circumferential position for the rotary valve, a first circle, centered on the axis of rotation, passes through the resilient element and the end stop.