Valve Unit Assembly Using Measured Disc Spacing Selection
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Solution Overview
Problem
The high dimensional tolerance requirements for valve units make precise manufacturing of individual components costly and restrictive, limiting the use of components with larger dimensional tolerances.
Innovation Solution
A method involving a 'measuring and selecting' principle where valve discs and tappets are partially assembled, and the disc clearance is measured to select a tappet guide that matches the sum of the disc spacing and predetermined stroke length, allowing for the assembly of high-precision valve units with larger tolerance ranges in components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If all separate components in a valve unit are manufactured with extreme precision, then the assembled valve unit achieves high dimensional tolerance compliance, but the manufacturing cost increases significantly
Solution Approach 1:
The patent changes the parameter approach by shifting from controlling individual component dimensions to controlling the sum of dimensions (stack-up). Instead of requiring each component to meet strict individual tolerances, the invention allows components to have larger individual tolerances while ensuring the cumulative dimension (e.g., total length of assembled parts) meets the required tolerance through selective assembly of pre-sorted components.
Solution Approach 2:
The patent applies preliminary action by measuring and sorting components before final assembly. Components are pre-measured and categorized into groups based on their dimensional values, then selectively combined during assembly to achieve the required cumulative tolerance. This pre-sorting approach eliminates the need for expensive high-precision manufacturing of each individual component.
2Ease of manufacture
If components are manufactured with larger dimensional tolerances, then manufacturing cost decreases, but the assembled valve unit may not meet precision requirements
Solution Approach 1:
The patent implements feedback through a sorting and selection process. Components with larger tolerances are measured, and the measurement results feed back into the assembly process by determining which specific components should be paired together. This feedback mechanism ensures that components are selectively combined to achieve the required cumulative precision, allowing individual components to have larger tolerances while maintaining overall assembly precision.
Solution Approach 2:
The patent introduces dynamics by making the assembly process adaptive rather than static. Instead of using fixed, high-precision components, the system dynamically selects and combines components with larger tolerances based on their measured dimensions, allowing the assembly to achieve required precision through flexible component selection rather than rigid manufacturing constraints.
3Reliability
If high-precision manufacturing is required for all components, then valve unit functionality is ensured, but device complexity and manufacturing process complexity increase
Solution Approach 1:
The patent applies segmentation by dividing the manufacturing process into two distinct stages: (1) mass production of components with larger, more economical tolerances, and (2) selective assembly of pre-sorted components. This segmentation allows the majority of the manufacturing process to use simpler, less expensive processes while reserving the more complex sorting and selection activities for a smaller portion of the overall process, thereby reducing overall manufacturing complexity while ensuring functionality.
Data Source
Figure 1a~1b
Figure 2a
Figure 2b
AI summary
A method for forming a valve assembly (3) is proposed, comprising the steps of: providing two valve disks (31, 37) each with a valve seat (32, 38); providing a valve tappet (34) with two opposing free ends (39a, 39b) corresponding to the valve seats (32, 38); providing tappet guides (33) of different dimensions; arranging the valve tappet (34) between the first valve disk (31) and the second valve disk (37) such that the two free ends (39a, 39b) seal the first valve seat (32) and the second valve seat (38), respectively; measuring a disk distance (S) between the first and second valve disks (31, 37) arranged in this manner, relative to the stroke direction (35);Selecting a tappet guide (33) from the plurality of tappet guides (33) such that a dimension of the selected tappet guide (33) related to the stroke direction (35) is equal to a sum of the measured disc spacing (S) and a predetermined stroke of the valve tappet (34).