Fuel control valve assembly

Abstract

A fuel control valve assembly that includes a ball bearing assembly and retainer assembly for a mixture control valve assembly and idle control valve assembly in use with general aviation fuel injector servos is disclosed. The assembly desirably reduces friction and wear on the components of the fuel control valve assembly.

Claims

1. A fuel mixture control assembly comprising: a shaft; a bushing; a roll pin; a stop bracket adapted to be secured adjacent one end of the shaft; a spring arranged over a portion of the shaft; a spring retainer adapted to retain a first end of the spring opposite the stop bracket; a retainer assembly opposed to the bushing; and a bearing assembly arranged substantially between the spring retainer and the retainer assembly.

2. The fuel mixture control assembly of claim 1, wherein the retainer assembly opposes the bearing assembly and the spring retainer opposes the bearing assembly.

3. The fuel mixture control assembly of claim 1, wherein the retainer assembly comprises a C-ring washer adapted to engage at least one notch in the shaft and a C-washer retainer sized to seat the C-washer.

4. The fuel mixture control assembly of claim 3, wherein the C-washer retainer further comprises a lip.

5. The fuel mixture control assembly of claim 1, wherein the bearing assembly comprises a thrust-bearing comprising a bearing race and a plurality of balls.

6. The fuel mixture control assembly of claim 5, wherein the bearing race comprises a plurality of spaces corresponding to each of the plurality of balls.

7. The fuel mixture control assembly of claim 5, wherein the bearing assembly comprises stainless steel.

8. The fuel mixture control assembly of claim 1, wherein the spring retainer comprises a rounded insert extending into a portion of an internal circumference of the spring.

9. The fuel mixture control assembly of claim 8, wherein the spring retainer comprises a shelf disposed about an outer circumference of the rounded insert.

10. The fuel mixture control assembly of claim 9, wherein the spring retainer comprises a flat surface opposite the rounded insert and the shelf.

11. The fuel mixture control assembly of claim 10, wherein the flat surface meets the bearing assembly.

12. The fuel mixture control assembly of claim 1, wherein the spring is made from stainless steel.

13. The fuel mixture control assembly of claim 1, further comprising a mixture control valve.

14. A fuel mixture control assembly comprising: a shaft; a bushing; a roll pin; a stop bracket adapted to be secured adjacent one end of the shaft; a spring arranged over a portion of the shaft; a spring retainer adapted to retain a first end of the spring opposite the stop bracket; a retainer assembly opposed to the bushing; and a bearing assembly arranged substantially between the spring retainer and the retainer assembly, wherein the retainer assembly opposes the bearing assembly and the spring retainer opposes the bearing assembly.

15. The fuel mixture control assembly of claim 14, wherein the bearing assembly comprises a thrust-bearing comprising a bearing race and a plurality of balls, the bearing race comprising a plurality of spaces corresponding to each of the plurality of balls.

16. The fuel mixture control assembly of claim 14, wherein the spring retainer comprises a rounded insert extending into a portion of an internal circumference of the spring, a shelf disposed about an outer circumference of the rounded insert, and a flat surface opposite the rounded insert and the shelf, whereby the flat surface meets the bearing assembly.

17. The fuel mixture control assembly of claim 1, further comprising a mixture control valve.

18. A fuel mixture control assembly comprising: a mixture control valve; a shaft; a bushing; a roll pin; a stop bracket adapted to be secured adjacent one end of the shaft; a spring arranged over a portion of the shaft; a spring retainer adapted to retain a first end of the spring opposite the stop bracket; a retainer assembly opposed to the bushing; and a bearing assembly arranged substantially between the spring retainer and the retainer assembly, wherein the retainer assembly opposes the bearing assembly and the spring retainer opposes the bearing assembly.

19. The fuel mixture control assembly of claim 18, wherein the bearing assembly comprises a thrust-bearing comprising a bearing race and a plurality of balls, the bearing race comprising a plurality of spaces corresponding to each of the plurality of balls.

20. The fuel mixture control assembly of claim 18, wherein the spring retainer comprises a rounded insert extending into a portion of an internal circumference of the spring, a shelf disposed about an outer circumference of the rounded insert, and a flat surface opposite the rounded insert and the shelf, whereby the flat surface meets the bearing assembly.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic cross-sectional view of a prior art fuel injection system.

(2) FIG. 2 is a cross-sectional view of a prior art mixture control assembly.

(3) FIGS. 3A and 3B are a cross-sectional view of a prior art idle control assembly from side and longitudinal perspectives, respectively.

(4) FIG. 4A is a side view of a prior art mixture control assembly.

(5) FIG. 4B is a perspective view of a prior art mixture control assembly.

(6) FIG. 4C is a cross-sectional view of a prior art mixture control assembly.

(7) FIG. 4D is a close-up cross-sectional view of a portion of the prior art mixture control assembly shown in FIGS. 4A-4C.

(8) FIG. 5A is a side view of a mixture control assembly according to one embodiment of the present invention.

(9) FIG. 5B is a perspective view of a mixture control assembly according to one embodiment of the present invention.

(10) FIG. 5C is a cross-sectional view of a mixture control assembly according to one embodiment of the present invention.

(11) FIG. 5D is a close-up cross-sectional view of a portion of the mixture control assembly shown in FIG. 5C according to one embodiment of the present invention.

(12) FIGS. 6A and 6B are a cross-sectional view of an idle control assembly according to one embodiment of the present invention from side and longitudinal perspectives, respectively.

(13) FIG. 7 is a perspective picture of a mixture control assembly according to one embodiment of the present invention.

(14) FIG. 8 is a perspective picture of a mixture control assembly according to one embodiment of the present invention.

(15) FIG. 9 is a close-up perspective picture of a mixture control assembly according to one embodiment of the present invention.

(16) FIG. 10 is a close-up perspective picture of a mixture control assembly according to one embodiment of the present invention.

(17) FIG. 11 is a close-up perspective picture of a mixture control assembly according to one embodiment of the present invention.

(18) FIG. 12 is a close-up perspective picture of a mixture control assembly according to one embodiment of the present invention.

(19) FIG. 13 is a perspective picture of the internal components of a mixture control assembly according to one embodiment of the present invention.

(20) FIG. 14 is a perspective picture of a mixture control assembly according to one embodiment of the present invention as modified for test purposes.

DETAILED DESCRIPTION

(21) The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Like numbers refer to like elements throughout. In the figures, certain components or features may be exaggerated for clarity, and broken lines may illustrate optional features or elements unless specified otherwise. In addition, the sequence of operations (or steps) is not limited to the order presented in the figures and/or claims unless specifically indicated otherwise. Features described with respect to one figure or embodiment can be associated with another embodiment or figure although not specifically described or shown as such.

(22) It will be understood that when a feature or element is referred to as being on another feature or element, it can be directly on the other feature or element or intervening features and/or elements may also be present. In contrast, when a feature or element is referred to as being directly on another feature or element, there are no intervening features or elements present. It will also be understood that, when a feature or element is referred to as being connected, attached or coupled to another feature or element, it can be directly connected, attached or coupled to the other feature or element or intervening features or elements may be present. In contrast, when a feature or element is referred to as being directly connected, directly attached or directly coupled to another feature or element, there are no intervening features or elements present. Although described or shown with respect to one embodiment, the features and elements so described or shown can apply to other embodiments. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms a, an and the are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms comprises and/or comprising, when used in this specification, specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. As used herein, the term and/or includes any and all combinations of one or more of the associated listed items and may be abbreviated as /.

(23) As used herein, phrases such as between X and Y and between about X and Y should be interpreted to include X and Y. As used herein, phrases such as between about X and Y mean between about X and about Y. As used herein, phrases such as from about X to Y mean from about X to about Y.

(24) Spatially relative terms, such as under, below, lower, over, upper and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations in use or operation in addition to the orientation depicted in the figures.

(25) It will be understood that although the terms first and second are used herein to describe various features or elements, these features or elements should not be limited by these terms. These terms are only used to distinguish one feature or element from another feature or element. Thus, a first feature or element discussed below could be termed a second feature or element, and similarly, a second feature or element discussed below could be termed a first feature or element without departing from the teachings of the present invention.

(26) Unless otherwise defined, all terms (including technical and scientific terms) and phrases used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the specification and relevant art and should not be interpreted in an idealized or overly formal sense unless expressly so defined herein. Well-known functions or constructions may not be described in detail for brevity and/or clarity.

(27) The term about, as used herein with respect to a value or number, means that the value or number can vary by +/ twenty percent (20%). The terms about, somewhat, etc., with respect to structural or functional inter-relations apart from values or numbers are used to convey that an absolute inter-relation is not required, so as the elements satisfy the described purpose within such inter-relation.

(28) Conventionally, as noted above, the frictional engagement inside the valve assembly of the washers, clips and bushings retained in place by the shaft and spring, impart minimal room for additions or modifications. In some embodiments of the present invention, a ball bearing assembly is included with a shortened spring that is comparably as strong as the prior art springs.

(29) FIGS. 5A-5D represent various embodiments of the present invention that reduce friction in the mixture control assembly. In some embodiments shown in FIG. 5D, the present invention includes a mixture valve assembly 55 including a spring retainer 50, a ball bearing assembly 61, a washer retainer 56, and a washer 57. Additional common parts to a mixture valve assembly may be includeda bushing 58 (that may be resized to fit the components of the various embodiments herein), a shaft 59, and a roll pin 60.

(30) In some embodiments, the cross-sectional design of the spring retainer 50 has a distinctive cross-sectional design. In some embodiments, the spring retainer 50 is includes a rounded insert 51 sized to extend into at least a portion of the internal circumference of the spring. In some embodiments, the spring retainer 50 includes a shelf 52 on one end of the spring retainer 50 including a circumference sized to accommodate and retain the spring. In some embodiments, the shelf 52 is rounded and of a circumference generally at or near the exterior circumference of the spring 54 (and of greater circumference than the insert 51). Opposite the rounded insert 51, the spring retainer 50 includes a flat surface 53 (extending along the shelf 52) for meeting the ball bearing assembly 61.

(31) The ball bearing assembly 61 in some embodiments includes a baring cage 63 with one or more balls 62 (e.g., stainless steel) sized to fit within ball-sized spaces in the cage 63. The ball bearing assembly 61 substantially reduces or eliminates friction in the operation of the mixture control assembly 55, thereby reducing jumpy control settings and/or foreign particle generation.

(32) In some embodiments, a washer retainer 56, includes a flat surface 65 for meeting the ball bearing assembly 61 opposite the spring retainer 50. Opposite the flat surface 65, the washer retainer 56 includes a seat 66 sized to fit a washer 57 (e.g., C-washer) that may lock into place along the shaft 59 opposite the bushing 58. The washer retainer 56 may also include a lip 67 to aid in retaining the washer 57.

(33) In some embodiments, the bushing(s) may be consistent in size with prior devices. In some embodiments, the bushing may be reduced in size to reduce the amount of change in size required of the spring. The spring 54 may be reduced in size (e.g., from 0.854 inch. to 0.684 inch.), while the strength increased to accommodate the reduction in size. FIGS. 7-12 show various pictures of the mixture valve assembly 55 of the present invention. FIG. 11 shows the washer 57 housed in a slot 80 of the shaft 59 for retaining the washer in place.

(34) FIG. 6 represents various embodiments of the present invention that reduce friction in the idle control assembly 70. In some embodiments, an idle control bearing assembly 71 may mirror the size and/or shape of the mixture control ball bearing assembly 61. In some embodiments, an idle control bearing assembly 71 includes an idle bushing 72 may be shaped to include a bushing seat 73 for retaining the idle control bearing assembly 71.

Testing

(35) A number of tests have been performed to evaluate the various improvements and effectiveness of certain embodiments of the presently disclosed ball bearing assembly for use in the idle valve assembly and/or fuel mixture assembly. Included herein below are two types of tests performed and their corresponding test results. In particular, included below are the methodology and results of various rotation torque tests and a Life Cycle Test.

(36) The testing described hereinbelow was conducted using the RSA series fuel injection servos manufactured by Precision Airmotive, LLC. The Teflon washers tested were Precision Airmotive part numbers 367757 and 2538330, respectively.

(37) Rotation Torque Tests:

(38) The force required to initiate movement of the mixture control lever and idle lever of RSA servos, respectively, were carefully measured using both the Teflon washer assembly of the prior art and an embodiment of the presently disclosed ball bearing assembly. The results were then compared to evaluate the effectiveness of certain embodiments of the presently disclosed ball bearing assemblies. Two different rotational torque tests were conducted: a test measuring the force required to initiate movement of the idle lever and mixture control lever in a full servo application, and a modified configuration with certain components removed so as to vary the amount of force on the Teflon washer or ball bearing assembly and measure the required rotational force under different compression/spring loads.

(39) First, the mixture control and idle lever assemblies were built up with their appropriate Teflon washers and installed into a servo body (valve area) with no fuel. The force required to initiate movement of the mixture control lever and idle lever, respectively, was then measured using this traditional configuration. The idle lever assembly was rotational torque tested with idle linkage lever part no. 2523299. The mixture control lever assemblies were tested with linkage lever part no. 2520672.

(40) The mixture control lever and idle lever were then removed, and the respective assemblies converted to an embodiment of the presently disclosed valve system comprising ball bearing assemblies. The levers were then reattached and each tested in the same manner.

(41) Table 1 contains the first test result data of the Rotation Torque Tests. The forces noted in Table 1 relate to all the components that rotate against each other when installed in a servo. Only a portion of the force is related to the friction between the Teflon thrust washer and the components that are pressed up against it. The same applies to the assemblies that were converted to use an embodiment of the thrust ball bearing assembly disclosed herein. In normal operation, the force applied to the thrust washers (or a ball bearing assembly used in place of the thrust washer assembly) is approximately 21 pounds. As Table 1 illustrates, significantly less force is required in the valve systems that include embodiments of the presently disclosed ball bearing assembly, resulting in significantly better control and operation of the valve systems.

(42) TABLE-US-00001 TABLE 1 Teflon Washer Ball Bearing Improvement Lever Type Configuration Configuration (%) Idle Lever 14 oz 10 oz .sup.40% Assembly Mixture 12 oz 8-10 oz 17-33% Control Lever

(43) To isolate how much friction is being imposed on the Teflon washer assembly or the replacement ball bearing assembly, a second test was performed with all items between the two arrows noted as components in FIG. 13 removed. Incrementally increasing weights were then attached to the outside of the idle lever assembly and the force required to initiate rotational movement were again recorded. FIG. 14 further illustrates this test configuration.

(44) Table 2 contains the test result data. As illustrated, the exemplary ball bearing assembly presently disclosed herein resulted in significant reductions in friction regardless of the amount of force imparted on the system.

(45) TABLE-US-00002 TABLE 2 Force Required to Initiate Movement Weight Applied Idle Lever with to Idle Lever Idle Lever with Ball Bearing Percentage Stem Teflon Washer Assembly Improvement 8.36 lbs 6 oz 2 oz 67% 18.36 lbs 12 oz 2 oz 83% 28.36 lbs 1 lbs, 2 oz (18 oz) 2 oz 89% 33.36 lbs 1 lbs, 8 oz (24 oz) 2 oz 92% 43.36 lbs 2 lbs, 4 oz (36 oz) 4 oz 89% 53.36 lbs 2 lbs, 12 oz (44 oz) 6 oz 86%

(46) Rotational Torque Test Summary:

(47) Both types of tests show that the exemplary embodiment of the presently disclosed ball bearing assembly can reduce the amount of force required to initiate rotational movement compared to that of the Teflon washer assembly in the prior art. When the idle lever assembly was loaded with various weights, the ability of the tested ball bearing assembly to outperform the Teflon washer assembly was apparent. The unique design of the bushings, reduced spring, and etched stainless steel thrust washers, in various embodiments, all work to ease resistance in operation, thereby providing various advantages in the system. These advantages include, among other things, maintaining the components in place, limiting vibration, matching the width specs of the prior art designs, and providing sufficient spring tension necessary to keep the components secured.

(48) Life Cycle Testing

(49) Life cycle testing was also performed on the prior version of the system and then compared to an improved version employing certain embodiments of the presently disclosed ball bearing assembly. Tests were conducted using two RSA-5DA1 servos with fully functional regulators and valve sections. Other test components included:

(50) a) Two test fluids: Stoddard per Mil-PRF-7024 type II and Avgas 100LL;

(51) b) Electric motors and linkage for cycling idle lever and mixture control levers;

(52) c) Flow bench with fuel lines, fuel pump, flow meters, pressure gauges, etc.;

(53) d) Idle lever assembly in stock configuration and idle lever assembly with ball bearing; and

(54) e) Mixture control lever assembly in stock configuration and mixture control lever assembly with ball bearing.

(55) Description of Testing:

(56) Two RSA-5AD1 servos with operational regulators and valve areas were used for cycle testing both the mixture control lever and idle lever assemblies. An electric motor with special linkage and bracket were attached to each servo. The electric motor and linkage allowed the lever assemblies to be cycled back and forth, as they would be on an aircraft. The servos were plumbed into a flow bench. During the day, test fluid was run through the units. At night, the fluid pump was turned off. The test fluid that was in the servos after shutting off the fluid pump remained in the units during overnight testing.

(57) The cycle rate at which the test lever assemblies were rotated through their full range of motion was 2.5 Hz. This rate is substantially higher than the rate at which the levers would normally be operated on the aircraft. For example, a pilot might move a lever 60 times in an hour, and only occasionally during operation would the levers would be moved through their full range of motion. The cycle rate of 2.5 Hz was therefore more stressful to the components located in the servo's valve area relative to normal operation. The idle and mixture control lever assemblies were removed from the servo's valve area periodically and inspected for wear.

(58) Testing occurred throughout the night with the test fluid remaining stagnate in the servo. This allowed wear particles to build up in the servo's valve area. This was desirable because it further taxed the normal wear surfaces beyond their normal use.

(59) Findings:

(60) Numerous components in the servo's valve area rotate against each other when the idle lever and mixture lever are moved. During testing, these components were removed at various time intervals to inspect for wear. As one example, the amount of wear was compared to the same components taken out of servo cores that were sent in for overhaul. It was found that 2,000,000 test cycles created wear that was indicative of servos that met the Time Between Overhaul (TBO) specifications, thereby demonstrating the improved functionality of various embodiments of the presently disclosed valve system having ball bearing assemblies included therein.

(61) The foregoing is illustrative of the present invention and is not to be construed as limiting thereof. Although a few exemplary embodiments of this invention have been described, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the claims. The invention is defined by the following claims, with equivalents of the claims to be included therein.