Spring Washer Structure to Limit Valve Mechanism Deformation Noise
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Solution Overview
Problem
Existing spring washers in variable flow rate valve mechanisms face issues with excessive deformation and noise generation due to collision between components, leading to reliability concerns, especially in turbocharger applications.
Innovation Solution
A spring washer design featuring a support portion, a deformable portion, and a protrusion portion is introduced, where the deformable portion is inclined and connected to the support portion, and the protrusion portion limits deformation by contacting components before excessive deformation occurs, thereby reducing plastic deformation and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the deformable portion is made more flexible to increase repulsive force, then the spring capability is improved, but excessive deformation and plastic deformation occur leading to reduced reliability
Solution Approach 1:
The protrusion portion performs preliminary action by contacting the pressing component before the deformable portion reaches its maximum deformation point. This pre-contact prevents excessive deformation and plastic deformation of the deformable portion, thereby maintaining reliability while preserving spring capability.
Solution Approach 2:
The protrusion portion acts as a beforehand cushioning element that absorbs excess pressing force before it can cause damage to the deformable portion. This cushioning mechanism prevents harmful effects while allowing the deformable portion to function within its elastic range.
2Force
If the deformable portion is pressed further to increase repulsive force, then the spring capability is improved, but collision noise is generated between components
Solution Approach 1:
The protrusion portion performs preliminary action by making contact with the pressing component first, preventing direct collision between the deformable portion and the pressing component. This eliminates collision noise while maintaining the spring washer's repulsive force capability.
3Force
If the deformable portion is made more flexible to increase repulsive force, then the spring capability is improved, but excessive deformation occurs reducing durability
Solution Approach 1:
The protrusion portion performs preliminary action by contacting the pressing component before excessive deformation occurs. This prevents the deformable portion from exceeding its elastic limit, thereby preserving durability while maintaining spring capability.
Solution Approach 2:
The protrusion portion provides beforehand cushioning that protects the deformable portion from excessive deformation. This cushioning action preserves the durability of the spring washer by preventing plastic deformation that would reduce its service life.
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 design enhances the reliability of variable flow rate valve mechanisms by inhibiting excessive deformation and collision noise, improving the stability and performance of turbochargers.
Implementation Method 1
When such a spring washer is pressed to cause the deformable portion and the support portion to approach each other in a parallel state, due to the deformation of the deformable portion, the spring washer generates a repulsive force to repel the pressing.
Data Source
AI summary
A variable flow rate valve mechanism includes a valve, a lock member, a valve attachment member and a spring washer. The valve includes a valve body and a valve shaft. The lock member is fixed to the valve shaft. The valve attachment member is attached to the valve shaft. The spring washer is disposed adjacent the valve attachment member. The spring washer is formed into an annular shape around an axis of the spring washer. The spring washer includes a support portion, a deformable portion and a protrusion portion. The support portion includes a seat surface and an open surface. The deformable portion is connected to the support portion and extends in an inclined manner. The deformable portion includes a contact surface and an opposite surface. The protrusion portion protrudes from at least one of the open surface of the support portion and the opposite surface of the deformable portion.