Motor Vehicle Turbo or Supercharger Diverter Valve System
20200332707 ยท 2020-10-22
Inventors
Cpc classification
F02B33/44
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K31/40
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B37/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K31/406
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K3/0218
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B33/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B29/083
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K31/383
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K1/38
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02B37/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B29/08
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B33/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B33/44
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16K31/383
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Turbo or super charged intake tract diverter valve system, upstream of a throttle valve, includes a closure means (10) for a diversion aperture (4.1) in the intake tract (3) to vent pressurised gases within to a bypass path or atmosphere; the closure means having a transfer aperture (12) facilitating a net three due to a pressure differential on its opposite sides of the closure means (10) so as to close or keep closed the diversion aperture (4.1). When gas pressure on opposite sides of the closure means is equal, and when an upstream side (10.1) of the closure means (10) has a pressure greater than a downstream side (5.1), then it will open the diversion aperture (4.1). An actuation means opens a control aperture (6) to create the necessary pressure differential on the closure means (10) to thereby cause same to open the diversion aperture (4.1).
Claims
1-29. (canceled)
30. A turbo or super charged intake tract diverter valve having a body comprising: a mounting flange having at least one mounting aperture there through; a generally cylindrical chamber formed in said body which is configured to receive a valve member; said valve member being generally cylindrical with a substantially closed end at one end, said substantially closed end having an aperture through the closed end; said body further comprising at least one transfer passage there through, the or each transfer passage ending in a port formed in said body; said valve member having a face seal which is bonded or adhered to said substantially closed end.
31. A valve as claimed in claim 30, wherein said substantially closed end of said valve member includes a circumferential bead.
32. A valve as claimed in claim 31, wherein said face seal and said circumferential bead are integrally formed of silicone and bonded to said valve member.
33. A valve as claimed in claim 30, wherein said face seal includes a circumferential bead.
34. A valve as claimed in claim 33, wherein said face seal is manufactured of silicone and bonded or adhered to said valve member.
35. A valve as claimed in claim 30, wherein said face seal is manufactured from silicone and bonded or adhered to said valve member.
36. A valve as claimed in claim 30, wherein said face seal is bonded silicone.
37. A valve as claimed in claim 30, wherein said valve body includes a frustoconical portion extending away from said mounting flange; and said generally cylindrical chamber is formed in said frustoconical portion.
38. A valve as claimed in claim 37, wherein said at least one transfer passage is formed through said frustoconical portion.
39. A valve as claimed in claim 37, wherein said port of said at least one transfer passage is elliptical in shape.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
[0055]
[0056]
[0057]
[0058]
[0059]
[0060]
[0061]
DETAILED DESCRIPTION OF THE EMBODIMENT OR EMBODIMENTS
[0062] As illustrated in
[0063] The valve body 1 contains a cylindrical wall 4 that is part of a bypass path 9 that leads back to the turbocharger compressor inlet. The wall 4 includes a chamber 5.1 which is formed by upper cylindrical wall 5.2 of cylindrical wall 4 and which is closed off by a wall 5 at the end within the valve body 1. The wall 5 contains a control aperture or hole 6, that allows the passage of air through it into a chamber 7 on the other side of the wall 5, and is bounded by the face of the solenoid coil body 2 when assembled. At least one transfer passage or passages 8 are included in the valve body 1 so as to allow passage of air from the chamber 7 to the outside of the valve body 1, via the recirculation passage or bypass path 9 when the valve is installed on a vehicle. It will be noted from
[0064] From
[0065] While it is preferred that there is only a single transfer or balance aperture 12 illustrated, it will be readily understood that more than one transfer or balance aperture 12 could be used, if more than one is used, then the sum of the cross sectional areas of each of the apertures will need to total at least 2 times smaller (that is be 50% or less) than the control aperture or hole 6 in the wall 5 of the valve body bore.
[0066] As best seen in
[0067] A main return compression spring 18 of suitable dimensions and specification is provided so as to produce additional bias or returning force to the piston 10. It is preferred that the return spring provides no pre-load when the piston 10 is in the closed position, or if a preload is provided it is greater than zero but up to and preferably not exceeding 0.2 kg of pre-load when the piston 10 is in the closed position, such as for the vehicles mentioned below. Pre-load is nil or if present is kept in the narrow range described so as to prevent or minimise the occurrence of turbo compressor surge. The spring rate should be such that the spring force is between 1-1.5 kg at maximum piston lift for such vehicles. However, for other vehicular engines these spring parameters may vary in accordance with the pressures in the system and other factors like the turbo specification. The exact spring force and rate (which is a function of spring dimensions) may need to be determined by trial and error to determine a maximum pre-load on the piston 10 prior to the onset of compressor surge. It is believed that no more than 0.2 kg of preload will prevent or minimise such compressor surge.
[0068] The compression return spring 18 can be given no pre-load in the valve system assembly by either the piston 10 being sized such that the dimensions of the chamber 5.1. or the non compressed height of the spring is sized, so that when piston and spring is assembled, and the piston 10 has closed off the diversion aperture 4.1, the return spring 18 is in an uncompressed state. Another way to ensure that no preload is provided by the return spring 18, is to have the uncompressed height of the spring 18 less than the height of the chamber 5.1 when the piston 10 is in the closed off position relative to the diversion aperture 4.1. This will ensure that for the last part of the stroke of the piston 10 to the closed position that the piston 10 is not under the urging of the return spring 18.
[0069] The valve of
[0070] Operation of the apparatus: Whenever the solenoid coil 2 is de-energised, the solenoid plunger 13 remains in a closed position as illustrated in
[0071] When the ECU energises the solenoid coil 2, the solenoid plunger 13 is retracted, thereby opening the control aperture or hole 6 in the wall 5 of the valve body 1, as is best illustrated in
[0072] When the ECU de-energises the solenoid coil 2, the plunger 13 moves back under the bias of the spring 15 so as to close the control aperture 6 and once again seals the valve body chamber 5.1, allowing pressure to equalise on both sides of the piston 10. With equal pressure but un-equal areas exposed to the pressure, the piston 10 is then forced closed again.
[0073] In the embodiment of
[0074] However, when the main return spring 18 is used, the main return spring 18 influences the size of the opening created by the piston 10 in response to the boost pressure present in the intake tract and communicated by the diversion aperture 4.1. If boost pressure is low, the piston 10 only opens a small amount of bypass opening, with the key objective being to vent only enough air to prevent pressure spikes. As the boost pressure is reduced by the action of bypassing, the piston 10 closes the diversion aperture 4.1 or decreases the size of the bypass opening, until there is no mere pressure and the piston 10 fully closes the diversion aperture 4.1, even when the ECU is energising the solenoid coil 2. If boost pressure is high when the ECU energises the solenoid coil 2, the piston 10 will open further than when the pressure is lower, to allow more air to recirculate. In this situation the size of the bypass passage or opening can be described as variable or dependent upon the amount of boost pressure to be diverted, unlike some of the prior art systems where the amount of opening of the valve is the same at all pressures due to the length of stroke of the direct acting solenoid.
[0075] In this way, the piston to is given a second means or parameter by which its opening stroke length is controlled. By opening only enough to prevent pressure spikes when the throttle is closed, but not completely evacuating the intake tract, turbo lag can be minimised. This means that the embodiment of
[0076] Key benefits of an after-market embodiment of the apparatus and method: 1. improved operation even under increased boost and operating temperature conditions; 2. simplified apparatus ensures a low-cost solution that is easy to install; 3. fast operational speeds because this apparatus does not require manifold vacuum to open, nor does it need vacuum hoses to be connected that would delay the pressure/vacuum signals; 4. utilizes the factory-supplied solenoid coil which means the benefits of the ECU control signal are retained, and a functioning solenoid coil is not wasted.
[0077] While the above description describes an after-market modification so as to use existing mounting systems and the like, it will also be understood that the diverter valve of the invention can be provided as an OEM diverter valve instead of the existing OEM diverter or bypass valves.
[0078] Key benefits of an OEM inventive embodiment of the apparatus and method: 1. reliable or improved operation even under increased boost and operating temperature conditions; 2. fast operational speeds because this apparatus does not require manifold vacuum to open, nor does it need vacuum hoses connected that delay the pressure/vacuum signals.
[0079]
[0099] The operation of the pilot or valve operating system as described above relies on a number of specific design criteria to function appropriately, as described below.
[0100] When the solenoid energises and the plunger 13 is retracted there by allowing airflow through the control aperture 6, and subsequently through chamber 7 and transfer hole/holes 8 must be greater than the airflow through the piston transfer aperture 12, such that pressure behind the piston 10 will be reduced to close to zero.
[0101] In a preferred embodiment the piston transfer aperture 12 has a diameter of approximately 2 mm, while the control aperture 6 has diameter of approximately 5 mm, and there are four transfer passages 8 each of approximately 3 mm in diameter. The cross-sectional area of the four transfer passages 8 is greater than that of the control aperture 6, thereby ensuring they create no additional downstream flow restriction or back pressure due to turbulence and/or the length of the transfer passages 8. Because the piston transfer aperture 12 is concentric to the control aperture 6, air passing through the piston transfer aperture 12 creates a jet that is directed into the control aperture 6, which entrains air from the surrounding chamber 5.1 which results in a slight vacuum in the chamber 5.1, thereby aiding the piston 10 moving to the open condition.
[0102] The plunger 13 forms part of the path that air must take to evacuate the piston chamber 5.1. and therefore the retract distance of the plunger 13 also plays a role in determining the total flow capacity of the control aperture 6. The plunger 13 must retract sufficiently so as not to restrict flow through the control aperture 6. A preferred retract distance of 1 mm to 2 mm will satisfy this.
[0103] The surface area that pressure gets to act upon on the upstream face of the piston is dictated by the diameter of the raised bead 11.1 of the moulded face seal 11. In the closed position, the raised bead 11.1 contacts the floor 9.1 (see
[0104] For the embodiment described above the preferred bead diameter of 19.5 mm can be utilised, while a piston outside diameter of 22 mm is also utilised, resulting in a face surface area (upstream) to piston surface area (downstream) ratio of 1:1.27, when calculated with the surface area of the transfer aperture 12 removed from the available surface areas. In an alternative embodiment a bead diameter of 21.5 mm can be utilised with a piston outside diameter of 24 mm, however this will result in a face surface area (upstream) to piston surface area (downstream) ratio of 1:1.247, when calculated with the surface area of the transfer aperture 12 is removed from the available surface areas.
[0105] Another parameter to be designed for is the speed at which the piston 10, will move from a closed to an open position. It is found that the parameters selected above will produce an appropriate speed of the piston 10 for effective opening of the diverter passage as a replacement for a factory solenoid diverter valve such as that manufactured by Pierburg for Volkswagen/Audi, where the valve of
[0106] As illustrated in
[0107] Illustrated in
[0108] While the above description and drawings show an O-ring seal 16 on the end of the plunger 13 it will be readily understood that the seal 16 could be positioned on or around the control aperture 6.
[0109] The valve body 1, can be manufactured from any appropriate material and any appropriate method of manufacture. While most preferred is machining the valve body 1 from aluminium, or other metals such as brass or stainless steel could be used or plastic; or it could be injection moulded in polymeric material, die cast or made from sintered metals. Metal deposition techniques could also be used and possibly 3D printing depending upon available polymers for such printing.
[0110] The piston 10 can be made from any appropriate material including aluminium, stainless steel or appropriate polymeric materials or metals.
[0111] Diverter valves as described above are commonly found in one of two locations, one is on a mounting flange that forms part of a supercharger or turbo compressor cover and includes a passage for incoming boost pressure, and one for the recirculation path. A second location used is a cast or machined mounting flange with the same inlet and outlet features but connected remotely to the intake via hoses.
[0112] While the above description is directed to embodiments which utilise a pre-existing solenoid to open or close the control aperture 6 or an OEM valve which uses a solenoid to do the same, it will be understood that other motive power means to open and close the control aperture 6 can be utilised such as pneumatic operation, whereby a negative pressure in the inlet tract is used to provide motive power to move a control valve member to take the place of the O-ring seal 16 and plunger 13.
[0113] Illustrated in
[0114] In the split system of
[0115] White the above embodiments describe the use of a bypass path in the diverter valve system, it will be understood that instead of a bypass path, the diverter system may divert to atmosphere.
[0116] In this specification, terms denoting direction, such as vertical, up, down, left, right, etc. or rotation, should be taken to refer to the directions relative to the corresponding Figure rather than to absolute directions unless the context require otherwise.
[0117] Where ever it is used, the word comprising is to be understood in its open sense, that is, in the sense of including, and thus not limited to its closed sense, that is the sense of consisting only of. A corresponding meaning is to be attributed to the corresponding words comprise, composed and comprises where they appear.
[0118] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.
[0119] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present inventor may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.