Control valve for an exhaust system and an exhaust system having such a control valve

Abstract

A control valve (10) for an exhaust system of a motor vehicle, especially a motorbike, comprising a valve housing (11) in which a shut-off body (12) is movably arranged for changing the cross-section of a flow channel (21) of the exhaust system, wherein expansion play in the radial and axial direction is provided between the shut-off body (12) and the valve housing (11), which allows thermal expansion of the shut-off body (12) within the valve housing (11), wherein the shut-off body (12) comprises a perforated ball (12a).

Claims

1. An exhaust system for a motor vehicle comprising a first exhaust pipe (20) which provides a first flow channel (21), and a control valve (10) comprising a valve housing (11) in which a shut-off body (12) is movably arranged for changing the cross-section of a flow channel (21) of the exhaust system, wherein expansion play in the radial and axial direction is provided between the shut-off body (12) and the valve housing (11), which allows thermal expansion of the shut-off body (12) within the valve housing (11), and the shut-off body (12) comprises a perforated ball (12a) wherein at least the shut-off body (12) is arranged in the first flow channel (21), and at least one second exhaust pipe (13) is provided which surrounds the first exhaust pipe (20) so that an annular space (32) is formed between the first exhaust pipe (20) and the second exhaust pipe (30), wherein the control valve (10) is arranged in such a way that at least one bypass channel (18) of the valve housing (11) is positioned in the annular space (32).

2. An exhaust system for a motor vehicle according to claim 1 wherein the valve housing (11) is formed in several parts.

3. An exhaust system for a motor vehicle according to claim 1 wherein the valve housing (11) and/or the shut-off body (12) comprises a hollow material or is formed therefrom.

4. An exhaust system for a motor vehicle according to claim 1 wherein the valve housing (11) comprises a middle cylindrical section (14) and two adjoining sections (15) formed in the manner of a truncated cone.

5. An exhaust system for a motor vehicle according to claim 1 wherein the shut-off body (12) is connected to an actuating shaft (16) or is integrally formed therewith, said actuating shaft extending through an opening (17) in the valve housing (11) to the outside.

6. An exhaust system for a motor vehicle according to claim 5 wherein the opening (17) is arranged in a cylindrical section (14) of the valve housing (11).

7. An exhaust system for a motor vehicle according to claim 5 wherein the actuating shaft (16) and the shut-off body (12) comprise materials that differ from each other.

8. An exhaust system for a motor vehicle according to claim 1 wherein the valve housing (11) comprises at least one bypass channel (18).

9. An exhaust system for a motor vehicle according to claim 1 wherein at least one seal is a metallic seal, and is arranged between the valve housing (11) and the shut-off body (12).

10. An exhaust system for a motor vehicle according to claim 1 wherein the shut-off body (12) is arranged in a floating manner in the valve housing (11) spaced on all sides from the valve housing (11).

11. An exhaust system for a motor vehicle according to claim 1 wherein the valve housing (11) comprises at least one bearing for the shut-off body (12) and/or the actuating shaft (16).

12. An exhaust system for a motor vehicle according to claim 1 further comprising a limit stop for limiting a rotational movement of the shut-off body (12).

13. An exhaust system for a motor vehicle according to according to claim 1 further comprising at least one spring element which acts on a rotational movement and/or a longitudinal axial displacement movement of the shut-off body (12) in the direction of flow so that the shut-off body (12) can be returned to a predetermined starting position.

14. An exhaust system according to claim 1 wherein the control valve (10) connects an inflow channel (22) to at least one outflow channel (23) so that a division of the volumetric flow from the inflow channel (22) into the outflow channels (23) is adjustable.

15. An exhaust system according to claim 1 wherein the first exhaust pipe (20), in the direction of flow of the exhaust gas, comprises a connecting opening (24) before and after the control valve (10), said connecting opening connecting the first flow channel (21) of the first exhaust pipe (20) to an annular space (32).

16. An exhaust system according to claim 1 wherein the control valve (10) is electronically controllable.

17. An exhaust system according to claim 1 wherein the control valve (10) is connected to a controller which predetermines the position of the shut-off body (12) depending on operating state data of the motor vehicle.

18. An exhaust system according to claim 17 wherein the controller comprises a standardised interface for connection with the motor vehicle.

19. An exhaust system according to claim 18 wherein the control valve (10) can be actuated by a servomotor, wherein the power supply of the servomotor occurs via the standardised interface.

Description

(1) The invention will be explained below in closer detail by reference to an embodiment shown in the enclosed schematic drawings, wherein:

(2) FIG. 1 shows a perspective total view of a control valve in accordance with the invention according to a preferred embodiment;

(3) FIG. 2 shows a part of the valve housing of the control valve according to FIG. 1;

(4) FIG. 3 shows a detailed view of the shut-off body of the control valve according to FIG. 1;

(5) FIG. 4 shows a perspective view of a part of an exhaust system with the control valve according to FIG. 1;

(6) FIG. 5 shows a cross-sectional view through a part of an exhaust system with the control valve according to FIG. 1;

(7) FIG. 6 shows a cross-sectional view of a detail of the control valve according to FIG. 1, and

(8) FIG. 7 shows a perspective view of an exhaust system with the control valve according to FIG. 1.

(9) The enclosed drawings show a control valve 10 for an exhaust system of a motor vehicle. The control valve 10 is preferably used in an exhaust system of a motorbike and allows changing the volumetric flow of the exhaust gases conducted through the exhaust pipe 20. Both the power of the motorbike and also the generation of noise can be influenced by a respective control of the control valve 10.

(10) The control valve 10 generally comprises a valve housing 11 in which a shut-off body 12 is arranged. The shut-off body 12 is formed in the illustrated embodiment as a perforated ball 12a. The shut-off body 12 which is formed as a perforated ball 12a is shown in detail in FIG. 3.

(11) The shut-off body 12 especially comprises a through bore 13, which substantially forms a cylindrical inner surface of the shut-off body 12. The through bore 13 is preferably dimensioned in such a way that its diameter corresponds to the diameter of an adjoining exhaust pipe 20. The outer surface of the shut-off body 12 is formed in a spherical manner or follows a spherical shape. As is further shown in FIG. 3, the shut-off body 12 comprises an actuating shaft 16, wherein the actuating shaft 16 is integrally formed with the shut-off body 12 or the perforated ball 12a. The actuating shaft 16 comprises a free end section in the illustrated embodiment, which end section has a polygonal, especially square, cross-sectional shape. In other words, the end section of the actuating shaft 16 has a square shape so that a respective actuating device can be connected in an interlocking manner to the actuating shaft 16. As is further shown in FIG. 3, a seal 12b rests on the outer surface of the shut-off body 12, which seal surrounds the actuating shaft 16. The seal 12b can substantially be formed by a curved washer.

(12) A bearing pin 19 is arranged radially opposite the actuating shaft 16, wherein the bearing pin 19 has a cylindrical outer contour. The bearing pin 19 preferably engages in a similarly cylindrical depression or opening 17 in the valve housing and thus fixes the longitudinal axial position of the shut-off body 12 in the valve housing 11. The actuating shaft 16 preferably also extends through an opening 17 in the valve housing 11, wherein at least the free end section, which is formed as a square, protrudes from the valve housing 11 and is thus connectable to an actuating device.

(13) Instead of the illustrated two-axis variant of the shut-off body 12 with a first actuating shaft 16 (first axis) and a bearing pin 19 (second axis), a single axis can generally be provided. In particular, the shut-off body 12 can exclusively comprise the actuating shaft 16 as the sole axis. In other words, the shut-off body 12 can be formed without the bearing pin 19.

(14) FIG. 1 shows the valve housing 11. The valve housing 11 comprises a cylindrical section 14 and two sections 15 formed in the manner of a truncated cone. The cylindrical section 14 is arranged between the two truncated-cone-shaped sections 15 and is rigidly connected thereto. The opening 17 is provided in the cylindrical section 14, through which the bearing pin 19 extends.

(15) The shut-off body 12 is arranged in the valve housing 11 at the altitude of the cylindrical section 14. The shut-off body 12 protrudes partly into the truncated-cone-shaped sections 15 in the longitudinal axial direction. It is generally provided that the valve housing 11 has a substantially spherical inner surface so that the shut-off body 12 can be twisted very well in the valve housing 11. In order to prevent jamming of the shut-off body 12, it is further provided that there is expansion play between the valve housing 11 and the shut-off body 12. It can be set by the seal 12b for example. For example, the seal 12b can have a wall thickness of between 0.2 mm and 0.5 mm, so that when using two seals 12b on the actuating shaft 16 on the one hand and the bearing pin 19 on the other hand an expansion play of 0.5 mm to 1 mm is maintained. An expansion play of 0.5 mm is preferable, wherein the shut-off body 12 has a distance of 0.25 mm from the valve housing 11 or the bearing bushes 25, through which the bearing pin 19 or the actuating shaft 16 are guided. FIG. 6 shows a bearing bush 25 by way of example, which is formed as a flanged sleeve bearing. The bearing bush 25 extends through the valve housing 11 and accommodates the actuating shaft 16. The actuating shaft 16 is connected to a cable guide 26. The cable guide to 26 accommodates a cable, especially a wire cable 27, which is pretensioned on the one hand by a spring 28 and is connected on the other hand to a servomotor for the actuation of the control valve. The spring 28 engages for this purpose in a loop 29, which is formed integrally from a longitudinal end of the wire cable 27. The fixing of the spring 28 occurs via a hook 37, which is attached or fixed to the second exhaust pipe 30 (FIG. 7).

(16) As is further shown in FIG. 1, the bypass channels 18 extend through the valve housing 11. The bypass channels 18 extend parallel to the longitudinal axial direction of the valve housing 11 or parallel to the direction of flow of a fluid flowing through the control valve 10. A total of six bypass channels 18 are especially provided, wherein three bypass channels 18 each form a group and the two groups of three bypass channels 18 each are arranged in a radially opposite manner. The function of the bypass channels 18 will be explained below in closer detail in the installed state by reference to FIG. 4.

(17) FIG. 2 shows a part or a half of the valve housing 11. The valve housing is preferably formed in several parts, especially in two parts. This facilitates mounting of the spherical shut-off body 12. For this purpose, the valve housing 11 is divided in the circumferential direction along the cylindrical section 14. The valve housing 11 is especially divided in such a way that the opening 17 is divided centrally both for the actuating shaft 16 and also for the bearing pin 19, so that each half of the valve housing 11 comprises two radially opposite, semicircular recesses, wherein the semicircular recesses, in the assembled state of the two halves of the valve housing 11, each form the openings 17 which are formed in a circular way. As a result, the shut-off body 12 with the actuating shaft 16 and the bearing pin 19 can simply be inserted into one half of the valve housing 11, and the valve housing 11 can then be completed by inserting the second half.

(18) As is also shown in FIGS. 1 and 2, the truncated-cone-shaped sections 15 are formed in a tapering manner to the outside. This is used for reducing the material on the one hand because the valve housing 11 thus entirely follows the spherical shape of the shut-off body 12. On the other hand, it allows the truncated-cone-shaped formation of the longitudinal axial ends of the valve housing 11 and the simple and compact integration of the control valve 10 in an exhaust system.

(19) FIG. 4 shows a part of an exhaust system which comprises two exhaust pipes 20, 30. A first exhaust pipe 20 is provided in particular, which is arranged coaxially within a second exhaust pipe 30. The second exhaust pipe 30 substantially forms a muffler. For this purpose, the second exhaust pipe 30 comprises a regular perforation extending over the entire circumference of the exhaust pipe 30. The first exhaust pipe 20 comprises an inflow channel 22, which is provided upstream of the control valve 10 in the direction of flow of the exhaust gas. The control valve 10 adjoins the inflow channel 22 directly. An outflow channel 23 of the first exhaust pipe 20 is provided downstream of the control valve 10 in the direction of flow. The outflow channel 23 is arranged coaxially within the second exhaust pipe 30.

(20) The first exhaust pipe 20 forms a first floor channel 21 for exhaust gases. The first exhaust pipe 20 comprises connecting openings 24 before the control valve 10 and after the control valve 10 in the direction of flow of the exhaust gas. The connecting openings 24 extend radially through the exterior wall of the first exhaust pipe 20.

(21) The connecting openings 24 connect the first flow channel 21 to a second flow channel 31 which is formed by the second exhaust pipe 30. It is specifically provided that as a result of the coaxial arrangement of the first exhaust pipe 20 within the second exhaust pipe 30 an annular space 32 is created, which is bounded on the one hand by the second exhaust pipe 30 and on the other hand by the first exhaust pipe 20. The connecting openings 24 in the first exhaust pipe 20 thus connect the first floor channel 21 to the annular space 32, which forms the second flow channel 31 of the second exhaust pipe 30.

(22) The second exhaust pipe 30 is formed in its entirety in an integral manner and comprises a connection piece 34 at its longitudinal axial end which faces the control valve 10. The connection piece 34 has a cross-sectional diameter which is greater than the cross-sectional diameter of a perforated middle section 36 of the second exhaust pipe 30. The connection piece 34 is especially dimensioned in such a way that it surrounds a truncated-cone-shaped section 15 of the control valve 10 or the valve housing 11 and is flush with said section. An end pipe 35 is provided at a longitudinally axially opposite end of the second exhaust pipe 30, which end pipe directly adjoins the perforated middle section 36 and has a cross-sectional diameter which is smaller than the cross-sectional diameter of the perforated middle section 36.

(23) FIG. 5 shows the control valve in the installed state in an exhaust system, wherein the flow path of the exhaust gases is especially shown in the cross-sectional view according to FIG. 5. The illustration clearly shows the valve housing 11 surrounds the shut-off body 12. The shut-off body 12 is formed as a perforated ball 12a, wherein the shut-off body 12 assumes the completely closed position in the illustration according to FIG. 5. The through bore 13 is twisted out of the first flow channel 21 so that no exhaust gases or only a small portion of the exhaust gas flow is conducted through the through bore 13. The control valve 10 is arranged between two pipe sections, wherein each pipe section is formed by a first exhaust pipe 20 and a second exhaust pipe 30 which surrounds the first exhaust pipe 20 coaxially. An annular space 32 is formed between the first exhaust pipe 20 and the second exhaust pipe 30, which annular space is fluid-connected to the bypass channels 18 in the valve housing 11. In other words, the bypass channels 18 of the valve housing 11 connect the annular spaces 32 of the second exhaust pipe 30 on both sides of the control valve 10. The bypass channels 18 thus form a second flow channel 31 with the second exhaust pipe 30 or the annular space 32.

(24) Radial connecting openings 24 are provided in the first exhaust pipe 20, so that the exhaust gas, in the closed state of the shut-off body 12, is introduced via the connecting openings 24 into the annular space 32. The exhaust gas can pass through the valve housing 11 via the bypass channels 18 and can subsequently return to the first flow channel 21 via connecting openings 24, which are arranged between the first exhaust pipe 20 and the second exhaust pipe 30 in a pipe section downstream of the control valve 10 in the direction of flow. The progression of the flow of the exhaust gas is shown in FIG. 5 by respective arrows.

(25) It is generally provided that the control valve 10 is arranged in such a way that it can shut off a flow path for exhaust gases in an exhaust system either in part or in full. It is not only possible to use the control valve for flow paths of exhaust gases, but also in flow paths for fuels, operating supplies, intake air, conditioning air or coolant. The control valve can be used not only as a shut-off or throttle valve. It is also possible to divide a fluid flow from an inflow channel 22 among one or several outflow channels 23. It can be recognised in the embodiment according to FIG. 5 that only one single inflow channel through the first exhaust pipe 20 is formed. The exhaust gas is conducted into the sole outflow channel 22 of the first exhaust pipe 20 by opening the shut-off body 12, i.e. by rotation of the shut-off body 12. It is alternatively possible to provide several outflow channels 23 after the control valve 10, so that a distribution of the exhaust gas to several outflow channels 23 is enabled by the rotation of the shut-off body 12.

(26) It is provided in the illustrated embodiment that the flow channel 21, 31 is respectively formed in a tubular manner with a substantially circular-cylindrical inner contour. It is also possible that the flow channel has a different cross-sectional geometry, e.g. a polygonal cross-sectional geometry.

(27) The control of the control valve 10 or the rotation of the shut-off body 12 can occur mechanically or manually. It is also possible to set the position of the shut-off body 12 by an electronically controlled controlling device. The electronically controlled controlling device can use different operating state data of the motor vehicle such as travelling velocity, engine speed and/or engaged transmission gears as operating state data for the calculation of the optimal opening degree of the control valve 10. The control valve 10 can thus be controlled dynamically. The aforementioned operating state data are preferably retrieved by a central interface on the vehicle. Such interfaces are diagnostic plugs, standardised data transmission interfaces and/or OBD plugs for example. The use of such a standardised data interface allows easily retrofitting the control valve 10 in existing vehicles.

(28) If no data for identifying the engaged transmission gear of the motor vehicle are available, the control of the control valve 10 can also occur on the basis of data which determine the travelling speed and the engine speed. These data allow drawing conclusions on the engaged transmission gear and thus also allow the dynamic control of the control valve 10.

LIST OF REFERENCE NUMERALS

(29) 10 Control valve 11 Valve housing 12 Shut-off body 12a Perforated ball 12b Seal 13 Through bore 14 Cylindrical section 15 Section shaped in the manner of a truncated cone 16 Actuating shaft 17 Opening 18 Bypass channel 19 Bearing pin 20 First exhaust pipe 21 First flow channel 22 Inflow channel 23 Outflow channel 24 Connecting opening 25 Bearing bush 26 Cable guide 27 Wire cable 28 Spring 29 Loop 30 Second exhaust pipe 31 Second flow channel 32 Annular space 33 Muffler 34 Connection piece 35 End pipe 36 Perforated middle section 37 Hook