VARIABLE VALVE MECHANISM FOR ENGINE

Abstract

For example, two intake valves for each cylinder each are driven by a selected one of cams via a corresponding rocker arm. Each rocker arm includes a support portion and a pressing portion (distal end portion). The support portion is rockably supported by a cylinder head. The pressing portion is configured to press a stem of the corresponding intake valve. The support portion of one of the rocker arms deviates to one side in an axis X direction (cam axial direction) with respect to the distal end portion. The support portion of the other one of the rocker arms deviates to the other side in the axis X direction with respect to the distal end portion.

Claims

1. A variable valve mechanism mounted on an engine, the variable valve mechanism comprising: a cam unit fitted around a camshaft, the cam unit including two sets of a plurality of cams, any one of the plurality of cams being selected by sliding the cam unit in an axial direction, two intake valves or two exhaust valves or both being provided for each cylinder; and rocker arms, each of the two intake valves or two exhaust valves or both being configured to be driven by the selected one of the cams via a corresponding one of the rocker arms, wherein each rocker arm includes a support portion rockably supported by a cylinder head of the engine, and a pressing portion configured to press a stem of a corresponding one of the valves, the support portion of any one of the two rocker arms for each cylinder deviates to one side in the axial direction of the camshaft with respect to the corresponding pressing portion, and the support portion of the other one of the rocker arms for each cylinder deviates to the other side in the axial direction of the camshaft with respect to the corresponding pressing portion.

2. The variable valve mechanism according to claim 1, wherein the cylinder head has mounting holes and insertion holes for each cylinder, the mounting holes are used to mount lash adjusters that respectively support the two rocker arms, the stems of the two valves are inserted through the insertion holes, and a distance between centers of the two mounting holes for each cylinder is longer than a distance between centers of the two insertion holes for each cylinder.

3. The variable valve mechanism according to claim 1, wherein the engine is a multi-cylinder engine.

4. The variable valve mechanism according to claim 3, wherein the cam units respectively corresponding to the adjacent cylinders are integrated with each other.

5. The variable valve mechanism according to claim 1, wherein a section having a smaller diameter than a base circle of a cam profile of each cam is provided within an angular range corresponding to an exhaust stroke of the corresponding cylinder in a base circle section of the cam profile.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Features, advantages, and technical and industrial significance of exemplary embodiments of the disclosure will be described below with reference to the accompanying drawings, in which like numerals denote like elements, and wherein:

[0019] FIG. 1 is a schematic configuration view of a valve actuating system for an engine in which a variable valve mechanism according to an embodiment of the disclosure is provided;

[0020] FIG. 2 is a perspective view that shows the basic configuration of an intake-side valve actuating system;

[0021] FIG. 3 is a cross-sectional view of a cam unit fitted around an intake camshaft;

[0022] FIG. 4 is a partially sectional view that shows the structure of the cam unit;

[0023] FIG. 5 is a view that illustrates the basic configuration of a cam changing mechanism that causes the cam unit to slide by engaging a shift pin with a guide groove;

[0024] FIG. 6 is a view that illustrates the operation of the cam changing mechanism;

[0025] FIG. 7 is an explanatory view that exaggeratedly shows the positional relationship between each rocker arm and a corresponding one of the cams when viewed from above a cylinder head;

[0026] FIG. 8 is a view that exaggeratedly shows the inclined arrangement of rocker arms according to the embodiment, and that corresponds to FIG. 7;

[0027] FIG. 9 is a view that exaggeratedly shows the positional relationship between valve insertion holes and adjuster mounting holes; and

[0028] FIG. 10 is an explanatory view of a cam profile according to another embodiment in which a relatively small-diameter section is provided in a base circle section of each cam.

DETAILED DESCRIPTION OF EMBODIMENTS

[0029] Hereinafter, an embodiment in which the disclosure is applied to a valve actuating system for an engine will be described. The engine 1 according to the present embodiment is, for example, an in-line four-cylinder gasoline engine 1. As schematically shown in FIG. 1, four first to forth cylinders 3 (#1 to #4) are arranged in the longitudinal direction of a cylinder block (not shown), that is, the front-to-rear direction (the horizontal direction of FIG. 1 indicated by the arrow) of the engine 1. In the following description, the front-to-rear direction of the engine 1 may be simply referred to as front-to-rear.

[0030] As shown from above in FIG. 1, a valve actuating system for intake valves 10 and a valve actuating system for exhaust valves 11 are arranged on the upper portion of the engine 1, that is, the upper portion of the cylinder head 2. That is, as indicated by the dashed lines in FIG. 1, the two intake valves 10 and the two exhaust valves 11 are provided for each of the four cylinders 3 arranged in line in the front-to-rear direction of the engine 1. The intake valves 10 are driven by an intake camshaft 12. The exhaust valves 11 are driven by an exhaust camshaft 13.

[0031] A variable valve timing (VVT) 14 is provided at the front end (left end in FIG. 1) of the intake camshaft 12, and another variable valve timing (VVT) 14 is provided at the front end of the exhaust camshaft 13. Each VVT 14 is able to continuously change valve timing. In addition, a cam changing mechanism (variable valve mechanism according to the aspect of the disclosure) is provided for each of the cylinders 3 on the intake camshaft 12. Each cam changing mechanism changes the lift characteristic of a corresponding one of the intake valves 10 by changing cams 41, 42 (see FIG. 2) for driving the intake valve 10.

[0032] For example, the first cylinder 3 (#1) is shown in FIG. 2 in enlarged view. As shown in the drawing, the two cams 41, 42 having different profiles are provided in correspondence with each of the two intake valves 10 arranged in the direction of the axis X of the intake camshaft 12 (cam axial direction, engine front-to-rear direction) for each cylinder 3. The low-lift cam 41 and the high-lift cam 42 are arranged from the left (one side in the axis X direction) toward the right (the other side) in FIG. 2. Any one of the low-lift cam 41 and the high-lift cam 42 is selected, and the intake valve 10 is driven via a rocker arm 15.

[0033] The base circles of these low-lift cam 41 and high-lift cam 42 have the same diameter, and are formed into mutually continuous circular arc faces. FIG. 2 shows a state where the roller 15a of the rocker arm 15 is in contact with the base circle section of the low-lift cam 41. In the rocker arm 15, the proximal end support portion 15b is rockably supported by the cylinder head 2 (not shown in FIG. 2) via a lash adjuster 16, while the distal end portion 15c (pressing portion) presses the top of the stem 10a of the intake valve 10 via a retainer 17.

[0034] That is, each intake valve 10 is a common poppet valve. The retainer 17 is provided at the upper portion of the stem 10a, and receives upward pressing force from a valve spring 18. Thus, as indicated by the continuous lines in FIG. 2, the head of each intake valve 10 closes an intake port (indicated by the imaginary line). The stem 10a of each intake valve 10 is inserted through a valve guide 19 fixed to the cylinder head 2.

[0035] As shown in FIG. 2, when the roller 15a is in contact with the base circle section and the intake valve 10 is not lifted, the distal end portion 15c of the rocker arm 15 is almost not pressing the corresponding intake valve 10. As the intake camshaft 12 rotates in the direction indicated by the arrow R from this state, the low-lift cam 41 presses the roller 15a to push the rocker arm 15 downward although not shown in the drawing. Thus, each intake valve 10 is lifted as indicated by the imaginary line in FIG. 2 against reaction force from the corresponding valve spring 18.

Overall Configuration of Cam Changing Mechanism

[0036] In the present embodiment, the cam that lifts the intake valve 10 via the rocker arm 15 as described above is set to any one of the low-lift cam 41 and the high-lift cam 42. That is, as shown in FIG. 3 to FIG. 5 in addition to FIG. 2, in the present embodiment, the sets of two cams 41, 42 are integrally provided at predetermined locations of a cylindrical sleeve 43 to constitute the cam units 4, and the sleeve 43 is slidably fitted around the intake camshaft 12.

[0037] As shown only in FIG. 1, in the present embodiment, the long sleeve 43 extends over the first cylinder 3 (#1) and the second cylinder 3 (#2), and the sets of two cams 41, 42 are respectively provided at locations corresponding to the two intake valves 10 of each of these cylinders 3, that is, four locations in total. That is, the two cam units 4 for the first cylinder 3 (#1) and the second cylinder 3 (#2) are integrally coupled to each other by the single sleeve 43. This also applies to the third cylinder 3 (#3) and the fourth cylinder 3 (#4).

[0038] FIG. 3 shows a cross section (cross section taken along the line III-HI in FIG. 4) near the middle of the cam unit 4 for the first cylinder (#1) in the axis X direction. As shown in FIG. 3, internal spline teeth are provided at the inner periphery of the sleeve 43, and are in mesh with external spline teeth provided at the outer periphery of the intake camshaft 12. That is, the cam units 4 (sleeve 43) are spline-coupled to the intake camshaft 12, and are configured to rotate integrally with the intake camshaft 12 and slide in the direction of the axis X.

[0039] In order to cause the cam units 4 to slide in that way, a guide groove 44 is provided at the outer periphery of the sleeve 43. A shift pin 51 is engaged with the guide groove 44 as will be described below. In the present embodiment, as shown in FIG. 2, FIG. 4, and the like, the clockwise spiral guide groove 44 is provided at the middle portion of the cam unit 4 for the first cylinder (#1) in the axis X direction. The guide groove 44 extends in the circumferential direction all around. Similarly, although not shown in the drawing, a counter-clockwise spiral guide groove is provided in the cam unit 4 for the second cylinder (#2).

[0040] An actuator 5 is arranged above the intake camshaft 12 in correspondence with each of the cylinders 3 and is supported by the cylinder head 2 via, for example, a stay 52 so that each shift pin 51 can be engaged with a corresponding one of the guide grooves 44. The stay 52 extends in the axis X direction. Each actuator 5 is configured to actuate a corresponding one of the shift pins 51 back and forth with the use of an electromagnetic solenoid. When the actuator 5 is in an on state, the shift pin 51 extends and engages with the guide groove 44.

[0041] For example, when the thus extended shift pin 51 is engaged with the guide groove 44, the shift pin 51 relatively moves in the circumferential direction on the outer periphery of the cam unit 4 and also moves in the axis X direction along the guide groove 44 (that is, obliquely) with the rotation of the intake camshaft 12, as will be described below additionally with reference to FIG. 6. At this time, actually, the cam unit 4 slides in the axis X direction while rotating.

[0042] More specifically, initially, as shown in FIG. 5, the guide groove 44 includes straight groove portions 44a, 44b and an S-shaped curved groove portion 44c. The straight groove portion 44a linearly extends in the circumferential direction at one side (left side in FIG. 5) in the axis X direction on the outer periphery of the cam unit 4. The straight groove portion 44b linearly extends in the circumferential direction at the other side (right side in FIG. 5) in the axis X direction on the outer periphery of the cam unit 4. The curved groove portion 44c connects these straight groove portions 44a, 44b with each other. As shown in FIG. 2, in the position in which the low-lift cam 41 is selected (low-lift position), the straight groove portion 44a at one side in the axis X direction faces the shift pin 51 of the actuator 5.

[0043] When the actuator 5 operates to cause the shift pin 51 to extend in this state, the shift pin 51 is engaged with the straight groove portion 44a located at one side of the guide groove 44 as shown in the top view of FIG. 6, and relatively moves downward in the drawing with the rotation of the intake camshaft 12. Then, as shown in the middle view of FIG. 6, the shift pin 51 reaches the curved groove portion 44c, and also moves to the other side in the axis X direction, that is, obliquely, while relatively moving downward in the drawing along the curved groove portion 44c.

[0044] Thus, actually, the shift pin 51 presses the cam unit 4 toward one side in the axis X direction to cause the cam unit 4 to slide, and switches the cam unit 4 into the position in which the high-lift cam 42 is selected (high-lift position). At this time, as shown in the bottom view of FIG. 6, the shift pin 51 reaches the straight groove portion 44b located at the other side of the guide groove 44, and, after that, leaves the guide groove 44. A sliding amount S of the cam unit 4 at the time of switching from the low-lift position to the high-lift position in this way is equal to the distance between the low-lift cam 41 and the high-lift cam 42 as shown in FIG. 5.

[0045] When the cam unit 4 is switched into the high-lift position as described above, the straight groove portion at the other side of the guide groove in the axis X direction, provided in the cam unit 4 for the second cylinder (#2), faces the shift pin 51 of the corresponding actuator 5 although not shown in the drawing. Then, by turning on the actuator 5 to cause the shift pin 51 to engage with the guide groove, it is possible to cause the cam unit 4 to slide to the other side in the axis X direction with the rotation of the intake camshaft 12 and move the cam unit 4 to the low-lift position similarly.

Lock Mechanism

[0046] In the present embodiment, a lock mechanism 6 is provided between each cam unit 4 and the intake camshaft 12. The lock mechanism 6 is used to hold the position of the cam unit 4 (the low-lift position or the high-lift position) at the time when the cams 41, 42 have been changed as described above. That is, as shown in FIG. 4, two annular grooves 43a, 43b are provided at the inner periphery of the sleeve 43 of each cam unit 4 side by side in the axis X direction (the horizontal direction of FIG. 4), and an annular protrusion 43c remains between the annular grooves 43a, 43b.

[0047] Two lock balls 61 are retractably arranged at the outer periphery of the intake camshaft 12 so as to be fitted to the annular groove 43a or the annular groove 43b when the cam unit 4 is in the low-lift position or the high-lift position. That is, in the present embodiment, a through-hole 12a extends through the intake camshaft 12 and opens at two locations on the outer periphery of the intake camshaft 12. The through-hole 12a has a circular cross section. The through-hole 12a accommodates the two lock balls 61 and a coil spring 62 inside.

[0048] Those two lock balls 61 are respectively arranged on both ends of the coil spring 62, and are urged by the spring force of the coil spring 62 so as to be pushed outward from openings at both ends of the through-hole 12a. Thus, when the cam unit 4 is in the low-lift position (the right-side position in FIG. 4) as shown in the top view of FIG. 4, the two lock balls 61 are fitted into the annular groove 43a to restrict a slide of the cam unit 4 and hold the cam unit 4 in the low-lift position.

[0049] On the other hand, when the cam unit 4 is in the high-lift position (the left-side position in FIG. 4) as shown in the bottom view of FIG. 4, the two lock balls 61 are fitted into the annular groove 43b to restrict a slide of the cam unit 4 and hold the cam unit 4 in the high-lift position. As described with reference to FIG. 6, when the cam unit 4, for example, slides from the low-lift position to the high-lift position, the lock balls 61 climb over the annular protrusion 43c and move from the annular groove 43a to the annular groove 43b.

[0050] At this time, as the cam unit 4 slides, the lock balls 61 are initially pushed by the annular protrusion 43c, move against the spring force of the coil spring 62, and leave the annular groove 43a. After climbing over the annular protrusion 43c, the lock balls 61 are fitted into the annular groove 43b under the spring force of the coil spring 62. This also applies to the case where the cam unit 4 slides from the high-lift position to the low-lift position.

Arrangement of Rocker Arms

[0051] Incidentally, with the structure that each cam unit 4 is slidably fitted around the intake camshaft 12 as in the case of the above-described cam changing mechanism, each cam unit 4 can slide due to reaction force from the valve springs 18 of the intake valves 10. That is, initially, as described with reference to FIG. 2, each rocker arm 15 rocks when the roller 15a provided at the middle portion of the rocker arm 15 is pressed by any one of the cams 41, 42, and causes the intake valve 10 to open via the retainer 17.

[0052] The rocker arm 15 that rocks in that way is arranged so as to be parallel to the cam indicated by the imaginary line (the low-lift cam 41 in FIG. 7; hereinafter, also simply referred to as cam 41), that is, so as to be perpendicular to the axis X (not shown in FIG. 7) of the intake camshaft 12 when viewed from above as shown in FIG. 7. However, actually, due to manufacturing tolerances, and the like, the cam 41 can be slightly inclined with respect to the rocker arm 15 as exaggeratedly shown in the drawing (the inclination angle is denoted by in the drawing).

[0053] If there is a misalignment with the cam 41 in this way, an unexpected slide of the cam unit 4 can occur under reaction force from the valve spring 18, which acts on the cam 41 via the rocker arm 15 and, by extension, the cam unit 4. That is, when the cam 41 rotates to rock the rocker arm 15 as described above, the cam 41 receives reaction force from the valve spring 18 via the rocker arm 15.

[0054] At this time, when the rocker arm 15 and the cam 41 are inclined with respect to each other as described above, the cam 41 is dragged in the direction of the axis X by the friction resistance between the rocker arm 15 and the cam 41 (in the present embodiment, the rolling resistance between the cam 41 and the roller 15a). In other words, the valve spring reaction force that acts on the cam 41 and, by extension, the cam unit 4, via the rocker arm 15 includes a component in the axis X direction. Thus, sliding force is added to the cam unit 4.

[0055] The magnitude of sliding force that is added to the cam unit 4 may be regarded as being proportional to the magnitude of friction resistance, so the sliding force increases as the reaction force from the valve spring 18 increases. The sliding amount may be expressed by (Perimeter of Cam 41)tan by using the inclination angle between the rocker arm 15 and the cam 41. The sliding amount increases as the inclination angle increases.

[0056] In the present embodiment, since the cams 41 corresponding to the two intake valves 10 in the cam unit 4 for each cylinder 3 are ground as one at the same time (this also applies to the cams 42), inclination with respect to the rocker arm 15 similarly occurs, and the direction of the drag at each of the two rocker arms 15 is the same. For this reason, sliding force that acts on the cam 41 and, by extension, the cam unit 4, tends to increase. If the sliding force overcomes the holding force of the lock mechanism 6, an unexpected slide of the cam unit 4 occurs.

[0057] In contrast, for example, it is also conceivable that the spring constant of the coil spring 62 of the lock mechanism 6 is increased or the annular grooves 43a, 43b into which the lock balls 61 are fitted are deepened. However, this increases resistance at the time of causing the cam unit 4 to slide in order to change the cams 41, 42, with the result that an engine rotation speed that is an upper limit for changing the cams 41, 42 decreases. In addition, the coil spring 62 is used in a high-stress state, so there is a concern that the durability of the coil spring 62 decreases.

[0058] In consideration of such a situation, in the present embodiment, arrangement of the two rocker arms 15 for each cylinder 3 is devised such that reaction force that acts on the cam unit 4 from the valve spring 18 and reaction force that acts on the cam unit 4 from the other valve spring 18 are set in the opposite directions along the axis X direction. With this configuration, since sliding forces that act on the cam unit 4 via the corresponding two rocker arms 15 are cancelled, an unexpected slide of the cam unit 4 is suppressed.

[0059] Specifically, as shown in FIG. 8 as an example, in the present embodiment, the support portion 15b of any one (the left side in the example of the drawing) of the two rocker arms 15 for each cylinder 3 deviates to one side (the left side in the drawing) in the axis X direction with respect to the distal end portion 15c, and the support portion 15b of the other one (the right side in the example of the drawing) of the rocker arms 15 deviates to the other side (the right side in the drawing) in the axis X direction with respect to the distal end portion 15c. In this way, the support portions 15b form a divergent shape in the drawing.

[0060] With this configuration, the valve spring reaction force that is input to the distal end portion 15c of the one of the rocker arms 15 and that acts on the cam 41 or the cam 42 (not shown in FIG. 8) as the rocker arm 15 rocks includes a component oriented toward one side in the axis X direction. The valve spring reaction force that acts on the cam 41 or the cam 42 via the other one of the rocker arms 15 includes a component oriented toward the other side in the axis X direction. Thus, both valve spring reaction forces cancel out each other.

[0061] In order to lay out the two rocker arms 15 in that way, in the present embodiment, when the cylinder head 2 is viewed from above as shown in FIG. 9 as an example, the positional relationship among adjuster mounting holes 2a and insertion holes for the two intake valves 10 is set as follows. The two lash adjusters 16 for each cylinder 3 are mounted in the adjuster mounting holes 2a. The insertion holes for the two intake valves 10 are valve insertion holes 2b through which the stems 10a of the intake valves 10 are inserted. The valve guide 19 of the intake valve 10 is fitted into each valve insertion hole 2b.

[0062] In FIG. 9, the adjuster mounting hole 2a at one side (the left side in the drawing) in the axis X direction deviates to one side in the axis X direction with respect to the valve insertion hole 2b, and the adjuster mounting hole 2a at the other side (the right side in the drawing) deviates to the other side in the axis X direction with respect to the valve insertion hole 2b. Thus, the distance D1 between the centers of the two adjuster mounting holes 2a is longer than the distance D2 between the centers of the two valve insertion holes 2b (the centers of the valve guides 19).

[0063] Generally, in the engine 1 as described in the present embodiment, the layout of the two intake valves 10 for each cylinder 3 is determined on the basis of the configuration of a corresponding combustion chamber, with the result that the distance D2 between the two valve insertion holes 2b is determined. If the distance D1 between the two adjuster mounting holes 2a is increased with respect to the distance D2, interference between the adjuster mounting holes 2a and the intake ports (not shown in FIG. 9) is easily avoided, so the flexibility of the shape and layout thereof increases.

[0064] In the above-described engine 1 according to the present embodiment, in the case where the cam changing mechanism that changes the two cams 41, 42 by sliding the cam unit 4 mounted on the intake camshaft 12 is provided, when the rocker arms 15 corresponding to the two intake valves 10 for each cylinder 3 are arranged so as to be inclined in opposite directions, reaction force that acts on the cam unit 4 from the valve spring 18 and reaction force that acts on the cam unit 4 from the other valve spring 18 act in opposite directions along the axis X direction and cancel out each other. Thus, it is possible to suppress an unexpected slide of the cam unit 4 due to valve spring reaction force.

Other Embodiments

[0065] The configuration of the disclosure is not limited to those described in the above embodiment. The embodiment is only illustrative, and the application, and the like, of the configuration of the disclosure are, of course, not limited. For example, in the embodiment, the low-lift cam 41 and the high-lift cam 42 are provided in the cam unit 4 for each intake valve 10, and the lift characteristic is switched in high and low two steps; however, the disclosure is not limited to this configuration. For example, the lift characteristic may be switched in three steps.

[0066] In the embodiment, the cam units 4 for the first and second cylinders 3 (#1, #2) are integrally coupled to each other by the sleeve 43, and, similarly, the cam units 4 for the third and fourth cylinders 3 (#3, #4) are also integrally coupled to each other; however, the disclosure is not limited to this configuration. The cam units 4 for the first to fourth cylinders 3 (#1 to #4) may be configured to slide independently of one another. In this case, each guide groove 44 may have various known shapes, such as a Y-shaped guide groove described in JP 2010-520395 A.

[0067] In the embodiment, in order to cancel out valve spring reaction forces that act on the cam unit 4 via the two rocker arms 15 for each cylinder 3 in the axis X direction, those two rocker arms 15 are inclined in opposite directions and are arranged so as to form a divergent shape in FIG. 9. Instead, the state of inclination of the two rocker arms 15 may be an inverted divergent shape in FIG. 9.

[0068] In order to suppress a drag of the cam 41 or cam 42 under the friction resistance between the cam 41 or cam 42 and the rocker arm 15, it is effective to devise the cam profile. That is, as shown in FIG. 10 as an example, a section A (indicated by the imaginary line in the drawing) having a smaller diameter than the base circle is provided within an angular range corresponding to the exhaust stroke of the cylinder 3 in the base circle section of the cam profile.

[0069] With this configuration, the friction resistance with the rocker arm 15 reduces in the small-diameter section, and a drag of the cam 41 or cam 42 is suppressed, so an unexpected slide of the cam unit 4 is difficult to occur. In an exhaust stroke, even when the degree of sealing of the intake valve 10 decreases in the small-diameter section, no inconvenience occurs. In FIG. 10, the entire angular range corresponding to the exhaust stroke of each cylinder 3 is set as the small-diameter section. Instead, part of the angular range corresponding to the exhaust stroke may be set as the small-diameter section.

[0070] Furthermore, in the embodiment, the example in which the cam changing mechanism is provided at the intake side in the valve actuating system of the engine 1 is described. Instead, the cam changing mechanism may be provided at the exhaust side or may be provided at both sides. The engine 1 is not limited to an in-line four-cylinder engine. The engine 1 may be an in-line two-cylinder, three-cylinder, five-cylinder or more. The disclosure is applicable to not only an in-line engine but also various cylinder arrangement engine, such as a V-engine.

[0071] The disclosure is able to suppress an unexpected slide of a cam unit due to reaction force from a valve spring in a cam-changing variable valve mechanism provided in a valve actuating system of an engine, and is highly effective when applied to, for example, an engine mounted on an automobile.