Valve Assembly Axial Wear Reduction via Non-Parallel Biasing

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Solution Overview

Problem

Valve systems in internal combustion engines experience wear due to axial movement of the valve shaft and plate caused by manufacturing clearances and external forces, leading to increased leakage and component wear, which existing stop devices fail to adequately prevent.

Innovation Solution

A valve assembly with a restricting device featuring a stop member and engagement member, where at least one surface is non-parallel to the axis, biases the valve shaft and plate axially to prevent movement in a specific direction, reducing wear by engaging the stop member and engagement member to stabilize the valve components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional stop device is used to prevent valve plate movement beyond first or second position, then the valve plate is biased in a third direction perpendicular to the second axis, but the valve shaft and valve plate can still move axially along the second axis causing wear on valve housing, valve shaft, and valve plate

Engineering Contradiction:

Improveprevention of valve plate movement beyond positionVSAvoidaxial movement causing wear

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The restricting device is divided into two functional components: a stop member that prevents movement beyond the first or second position (traditional function), and an engagement member that prevents axial movement along the second axis (new function). This segmentation allows each component to address specific wear issues independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The engagement member acts as an intermediary element between the valve shaft and the stop member. It engages with the stop member through a non-parallel surface to transmit biasing force that prevents axial movement of the valve shaft and valve plate, thereby reducing wear without compromising the stop function.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If holding current is applied to the actuator to increase bias of the valve shaft against valve housing or bushing, then axial movement is reduced, but wear on the valve shaft, valve housing, and bushing increases

Engineering Contradiction:

Improveaxial movementVSAvoidwear on valve shaft and housing

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The function of preventing axial movement is extracted from the actuator's holding current mechanism and transferred to the restricting device. The engagement member and stop member work together to provide the necessary biasing force, eliminating the need for continuous holding current and reducing wear on the valve shaft and housing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The engagement member and stop member are designed as simple mechanical components that provide the necessary constraint through their geometric relationship. This simple mechanical solution replaces the complex and wear-prone actuator holding current mechanism.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If the plate width is made less than the bore diameter to allow thermal expansion and contraction, then thermal movement is accommodated, but manufacturing clearances and external forces cause axial movement along the second axis

Engineering Contradiction:

Improvethermal expansion accommodationVSAvoidaxial movement due to clearances and vibrations

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The restricting device provides dynamic constraint while allowing thermal movement. The engagement member and stop member are positioned such that they prevent axial movement during operation but do not constrain the valve plate's ability to expand and contract thermally. The non-parallel surface of the engagement member allows for controlled movement within the bore.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS10041420B2Valve assembly and valve system including same

Publication Date: 2018.08.07 BORGWARNER INC

AI summary

A valve assembly includes a valve housing defining a bore with a first axis extending along a length of the bore, and a valve shaft partially disposed within the bore along a second axis that is perpendicular to the first axis. The valve assembly additionally includes a valve plate coupled to the valve shaft and disposed within the bore, and a restricting device including a stop member and an engagement member. The stop member extends from the valve housing and presents a stop surface. The engagement member extends from the valve shaft and presents an engagement surface. At least one of the stop surface and the engagement surface is non-parallel with the second axis. The at least one non-parallel surface engages the other of the stop member and the engagement member and biases the valve shaft axially along the second axis.