Patent Grant
9897043
The present invention relates to an air pump used for diagnosing a leak by utilizing a pressure fluctuation of automobile piping, a module configured by the air pump, and an evaporated fuel processing system that uses the air pump.
For the purpose of preventing air pollution, an evaporation system (evaporated fuel processing system) for processing evaporated gas is mounted to an automobile to prevent the evaporated gas (evaporated fuel) generated in a fuel tank from being released into the atmosphere.
In North America, it is further prescribed by law to check whether or not an abnormality such as breakage, a crack, or a hole is present in piping itself of the evaporation system at a specific frequency. Accordingly, it is necessary to perform a leak diagnosis with the piping of the evaporation system and the following method is generally used: a pressure is applied to the piping of the evaporation system in a sealed state, and a fluctuation of the pressure is monitored.
The method in which the pressure is applied to the piping of the evaporation system during the leak diagnosis differs depending on an automobile manufacturer, and the method includes a method that uses an air pump and a method that uses a pressure fluctuation caused by natural heat radiation.
While the leak diagnosis in the case of using the natural heat radiation is capable of performing the diagnosis without generating a noise, there are disadvantages that a long diagnosis time increases total power consumption and also that a sufficient diagnosis frequency cannot be secured.
On the other hand, the leak diagnosis in the case of using the air pump can be carried out in a short time period to thereby achieve power saving and secure the sufficient diagnosis frequency. However, as described about a configuration for absorbing an operation sound of a leak diagnosis apparatus in Patent Document 1, and a configuration for alleviating a collision inside a leak diagnosis apparatus in Patent Document 2, there occurs a problem that a noise is generated during the diagnosis. Since the leak diagnosis in the case of using the air pump is performed under a quiet condition during stop of an engine, the noise during the diagnosis, in particular, poses a problem as an abnormal noise.
Note that Non-Patent Document 1 describes a general sound absorbing structure that absorbs sound, but is not limited to the noise generated during the leak diagnosis.
As described above, the leak diagnosis in the case of using the air pump has the problem of the noise generation during the diagnosis, and there exist various noise generation sources. For example, a check valve provided in the air pump also is one of the generation sources, and a vibration of the check valve during operation of the air pump generates the noise.
The present invention has been made in order to solve the above problem, and an object thereof is to reduce the noise generated from the check valve of the air pump during the leak diagnosis.
An air pump according to the invention changes, for a leak diagnosis, an internal pressure of an evaporated fuel processing system that collects evaporated fuel generated in a fuel tank to introduce the collected evaporated fuel into an engine, and includes: a housing provided with an opening portion communicating with the evaporated fuel processing system and an opening portion communicating with an air side; a check valve disposed between the two opening portions of the housing to prevent a backflow of discharged gas; and a partition plate in which a hole serving as a first reducing part is opened and which is disposed at the opening portion from which the gas is discharged out of the two opening portions of the housing, to separate an inside from an outside of the housing, wherein a pipe in which a hole is formed is protrusively provided in the partition plate, and the pipe is extended toward the check valve to constitute a second reducing part with the pipe and the check valve.
A module according to the invention includes: an electromagnetic valve that opens and closes a flow path connecting an air side and an evaporated fuel processing system that collects evaporated fuel generated in a fuel tank to introduce the collected evaporated fuel into an engine; an air pump that changes an internal pressure of the evaporated fuel processing system for a leak diagnosis; and a case that contains the electromagnetic valve and the air pump, wherein the air pump has a housing provided with an opening portion communicating with the evaporated fuel processing system and an opening portion communicating with the air side, and a check valve disposed between the two opening portions of the housing to prevent a backflow of discharged gas, and one surface of the case is a partition plate in which a hole serving as a first reducing part is opened and which faces the opening portion from which the gas is discharged out of the two opening portions provided in the housing of the air pump, to separate an inside from an outside of the housing, wherein a pipe in which a hole is formed is protrusively provided in the partition plate, and the pipe is extended toward the check valve to constitute a second reducing part with the pipe and the check valve.
An evaporated fuel processing system according to the invention collects evaporated fuel generated in a fuel tank to introduce the collected evaporated fuel into an engine, and includes: an air pump that changes an internal pressure of the evaporated fuel processing system for a leak diagnosis; and an insertion opening into which the air pump is inserted, wherein the air pump has a housing provided with an opening portion communicating with the inside of the evaporated fuel processing system and an opening portion communicating with an air side, and a check valve disposed between the two opening portions of the housing to prevent a backflow of discharged gas, and the insertion opening has a partition plate in which a hole serving as a first reducing part is opened and which faces the opening portion from which the gas is discharged out of the two opening portions provided in the housing of the air pump, to separate an inside from an outside of the housing, wherein a pipe in which a hole is formed is protrusively provided in the partition plate, and the pipe is extended toward the check valve to constitute a second reducing part with the pipe and the check valve.
According to the invention, the partition plate is adapted to separate the inside from outside of the housing on the side of the opening portion from which the gas is discharged out of the opening portions provided in the housing of the air pump, to thereby form a space for sound reduction on a downstream side of the check valve, and hence it is possible to reduce noise generated from the check valve of the air pump during the leak diagnosis.
Hereinbelow, in order to describe the invention in greater detail, the best mode for carrying out the invention will be described according to the accompanying drawings.
An evaporation system shown in
The leak diagnosis of the piping system 6 is performed by using a leak diagnosis apparatus that includes an electromagnetic valve 11 that opens and closes a pipe that provides communication between the piping system 6 and an air side, an air pump 12 that introduces the air into the piping system 6 from the air side to pressurize the inside of the piping system 6, a pressure gauge 13 that detects a pressure in the piping system 6, and a temperature gauge 14 that detects a temperature inside the piping system 6. In addition, a check valve 121 that prevents a backflow of compressed air discharged by the air pump 12 is provided between the air pump 12 and the piping system 6. In Embodiment 1, the air pump 12 and the check valve 121 are provided by an integrated structure.
In the air pump 12, a rotor 123 that rotates a plurality of vanes 122, a first housing 124 made of resin that accommodates the vanes 122 and the rotor 123, and a motor 126 that is fixed to the first housing 124 with a metal plate 125 interposed between the motor and the first housing 124 to rotationally drive the rotor 123 are provided. The motor 126 is contained in a case 128 having a connector 127. In addition, an intake opening portion 129 that communicates with the air side to take in the air is provided in the first housing 124, and a filter 130 is mounted to the intake opening portion.
A bottom surface side of the first housing 124 is covered with a second housing 131 which is a plate-like component made of resin, and a third housing 132 which is a cylindrical component made of resin is further mounted to the second housing. The second housing 131 and third housing 132 are fastened to the metal plate 125 together with the first housing 124 with screws not shown.
An opening portion 133 through which the air having entered from the intake opening portion 129 passes is provided in the second housing 131, and an opening portion 135 through which the air having entered from the opening portion 133 passes is provided in a partition wall 134 of the third housing 132. A sponge-like filter 136 is provided in a space formed between the second housing 131 and partition wall 134 of the third housing 132. In addition, an outer side of the partition wall 134, that is, a lower portion of the third housing 132, serves as an exhaust opening portion 137 that communicates with the piping system 6, and a partition plate 139 made of, e.g., resin that separates the inside from outside of the third housing 132 is provided in the exhaust opening portion 137. A hole 138 is formed in the partition plate 139, and the hole 138 allows passage of the air having entered from the opening portion 135.
A shaft end portion of the check valve 121 passes through and is engaged with the partition wall 134 of the third housing 132. In addition, an umbrella-shaped valve body of the check valve 121 is positioned in the exhaust opening portion 137, and receives the pressure of the air flowing in from the opening portion 133 by the operation of the motor 126 to open the opening portion 135, and closes the opening portion 135 when receiving the pressure from the piping system 6.
An O-ring 140 is provided on an outer peripheral surface of the third housing 132, and an O-ring 141 is provided on an outer peripheral surface of the case 128. When the air pump 12 is used by mounting it to a component other than the air pump 12 such as a pipe that connects the canister 2 and the air side, the O-rings are provided in order to seal such mounting portions to thereby prevent the air discharged to the side of the piping system 6 from the exhaust opening portion 137 from leaking from the mounting portions.
A description will be given of a flow during the leak diagnosis by the leak diagnosis apparatus having the air pump 12 configured as described above. The air pump 12 may be mounted to any position as long as the position allows pressurization of the inside of the piping system 6. For example, the air pump 12 may be mounted to the fuel tank 1, the canister 2, the filter 5, or the pipe of the piping system 6 indicated by a thick line in
During the leak diagnosis, the air pump 12 is driven with the purge solenoid valve 4 and the electromagnetic valve 11 closed. In the air pump 12, the air is sucked from the air side to the intake opening portion 129 by the rotation of the vanes 122 caused by the rotation of the motor 126, and the air is discharged to the opening portion 133. When the air having passed through the opening portion 133 further passes through the filter 136, dust thereof is removed, and the air is discharged from the opening portion 135. Subsequently, the air is discharged from the hole 138 of the partition plate 139 provided in the exhaust opening portion 137 to the side of the canister 2, and the inside of the piping system 6 is pressurized. In this manner, the pressure in the piping system 6 is put in a state different from atmospheric pressure.
During driving of the air pump 12, the check valve 121 repeatedly opens and closes the opening portion 135 in a state in which a large pressure difference between front and back of the check valve 121 occurs, and hence a vibration of the check valve 121 caused by flow pulsation is increased, so that a noise is generated. At this point, a space R1 separated from the outside of the third housing 132 by the partition plate 139 is formed on a downstream side of the check valve 121, and the noise generated by the vibration of the check valve 121 goes out from the hole 138 with the noise reduced in the space R1. Consequently, the noise to be traveled to the outside of the air pump 12 is made smaller as compared with the case where the partition plate 139 is not provided.
A frequency f0 (Hz) of the noise reduced at this point can be calculated by the following Expression (1) on the assumption that the space R1 separated from the outside of the third housing 132 by the partition plate 139 to be formed on the downstream side of the check valve 121 is in the shape of a rectangular parallelepiped:
In Expression (1), L (m) is the distance from the partition wall 134 to the partition plate 139, and a (m/s) is the velocity of sound. When the position of the partition plate 139, namely the distance L, is set such that the frequency f0 matches the frequency exhibiting the peak of the noise generated by the vibration of the check valve 121, the noise can be reduced effectively.
In addition, when an opening area of the hole 138 of the partition plate 139 is set to a proper value, it is possible to generate a pressure difference between the inside and the outside of the third housing 132 with the partition plate 139 serving as the boundary. That is, it is possible to change stepwise the pressure in a path from the downstream side of the check valve 121 to the canister 2. An opening area S (m2) of the hole 138 capable of generating the pressure difference can be calculated by the following Expression (2):
In Expression (2), Q is the flow rate (L/min) of the air discharged by the air pump 12, and ρ is the density (kg/m3) of the air discharged by the air pump 12.
When the pressure in the path from the downstream side of the check valve 121 to the canister 2 is changed stepwise, the pressure difference between front and back of the check valve 121 can be reduced to thus suppress the vibration of the check valve 121 caused by the flow pulsation. As a result, the noise generated by the vibration can be made smaller.
For example, in the case where the generated noise is reduced by a sound absorbing member, the frequency having a sound reduction effect is limited. However, the sound reduction effect is equally obtained irrespective of the frequency when the vibration itself is suppressed with the partition plate 139. The sound quality of the noise generated by the vibration of the check valve 121 differs depending on, for example, dimensional variations of the check valve 121 and peripheral components of the check valve 121, an atmosphere temperature, and degradation over time, and hence, in light of such conditions, in addition to the configuration in which the sound reduction effect is exerted in the specific frequency by adjustment of L in Expression (1), the sound reduction effect is enhanced when the following configuration is adopted: the vibration itself is suppressed by adjustment of S in Expression (2), so that the sound reduction effect is equallly obtained, irrespective of the frequency.
In the leak diagnosis, the pressure inside the piping system 6 is monitored by the pressure gauge 13, and the operation of the air pump 12 is stopped at a point of time when a pressure difference between the pressure and atmospheric pressure is generated up to a state that allows the leak diagnosis. At this point, since the pressure on the side of the exhaust opening portion 137 that communicates with the piping system 6 is higher than the pressure on the side of the space in which the filter 136 is disposed, the check valve 121 closes the opening portion 135 due to the pressure difference and completely seals the piping system 6 to thereby maintain a high-pressure state. A pressure fluctuation in the piping system 6 in the completely sealed state is compared with that serving as a reference in the case where a leak occurs, and it is thereby possible to diagnose presence or absence of the leak occurrence. The pressure fluctuation serving as the reference in the case where the leak occurs is corrected by a pipe volume of the piping system 6, a fuel amount in the fuel tank 1, the temperature monitored by the temperature gauge 14, and so on.
As mentioned above, when the partition plate 139 having the hole 138 is provided in the exhaust opening portion 137 to separate the inside from outside of the third housing 132, it is possible to reduce the noise generated due to the vibration of the check valve 121 caused by the flow pulsation.
In addition, when the opening area of the hole 138 provided in the partition plate 139 is set to the proper value, the vibration of the check valve 121 caused by the flow pulsation can be suppressed to thus reduce the noise generated due to the vibration of the check valve 121.
Further, the provision of the partition plate 139 can prevent the dust from the piping system 6 from adhering to the check valve 121.
Furthermore, it is only necessary to provide the partition plate 139, and hence a noise countermeasure can be implemented inexpensively.
Note that, though the configuration in which the hole 138 is provided in the partition plate 139 has been described, as shown in
In addition, as shown in a plan view and a cross-sectional view in
Further, as shown in a cross-sectional view in
Furthermore, as shown in a plan view and a cross-sectional view in
In the partition plate 139, the position, size, and shape, and the number of the hole 138, pipe 142, and rib 144 are not limited to those shown in
In addition, as the following configuration is shown in
Further, in each of the configurations shown in
As described above, according to Embodiment 1, the partition plate 139 having the hole 138 is provided in the exhaust opening portion 137 provided in the third housing 132 of the air pump 12 to separate the inside from outside of the third housing 132, so that the space R1 is formed on the downstream side of the check valve 121. Since the noise generated by the vibration of the check valve 121 is reduced in the space R1, it is possible to reduce the noise generated from the check valve 121 of the air pump 12 during the leak diagnosis.
In addition, it is adapted that the hole 138 of the partition plate 139 has the opening area that generates the pressure difference between the inside and outside of the third housing 132 with the partition plate 139 serving as the boundary. Consequently, the pressure is changed stepwise in the path that passes through the piping system 6 from the downstream side of the check valve 121, whereby the pressure difference between front and back of the check valve 121 can be reduced to thereby suppress the vibration of the check valve 121 caused by the flow pulsation. As a result, the noise generated by the vibration can be diminished.
Further, it is adapted that the plurality of the holes 138 are formed in the partition plate 139. Consequently, when the opening area of each of the holes 138 is made smaller, it is possible to further make the dust from the piping system 6 less likely to adhere to the check valve 121.
Furthermore, it is adapted that the pipe 142 is protrusively provided in the partition plate 139. Consequently, it is possible to further enhance the sound reduction effect to the noise generated by the vibration of the check valve 121.
Additionally, it is adapted that the ribs 144 are protrusively provided on the surface of the partition plate 139 that faces the check valve 121. Consequently, it is possible to further enhance the sound reduction effect to the noise generated by the vibration of the check valve 121.
In addition, it is adapted that the sound absorbing member 143 is provided on the surface of the partition plate 139 that faces the check valve 121. Consequently, it is possible to further enhance the sound reduction effect to the noise generated by the vibration of the check valve 121.
Though in Embodiment 1, the case where the leak diagnosis is performed with the air pump 12 singly mounted to another component such as the pipe has been described, the air pump 12 may also be mounted with integrated with the electromagnetic valve 11.
The electromagnetic valve 11 has a core 111 that is excited when a coil 110 is energized, a plunger 112 that can reciprocate by magnetic attraction of the core 111, and a rod 113 that is supported in the core 111 and interlocked with the plunger 112. In addition, in a housing 118 of the electromagnetic valve 11, a valve seat 114, a first opening portion 115 that communicates with the first port 161 of the case 16, a second opening portion 116 that communicates with the second port 162 of the case 16, and a third opening portion 117 that communicates with an intake opening portion 129 of the air pump 12 are formed. Further, inside the housing 118, a valve body 119 that is fixed to an end of the rod 113, a spring 120 that constantly biases the valve body 119 in a valve opening direction, and the like are disposed.
At the time of excitation, the valve body 119 moves to the side of the valve seat 114 to establish a valve closed state, and the first opening portion 115 and second opening portion 116 of the housing 118 are blocked from each other. Note that, even when the electromagnetic valve 11 is closed, communication between the first opening portion 115 and third opening portion 117 is established via a space in which the spring 120 is prepared.
The air pump 12 is contained in the case 16 when the case 128 shown in
A description will be given of a flow during a leak diagnosis by a leak diagnosis apparatus having the module 15 configured as described above. Similarly to the description in Embodiment 1, the module 15 may be mounted to any position as long as the air pump 12 can pressurize the inside of the piping system 6.
During the leak diagnosis, while the electromagnetic valve 11 is closed and the first opening portion 115 and second opening portion 116 are blocked from each other, the air pump 12 sucks from the intake opening portion 129, the air having passed through the first port 161, the first opening portion 115, the space in which the spring 120 is provided, and the third opening portion 117.
The air sucked from the intake opening portion 129 passes through the filter 145 and the hole 164 provided in the wall 163 of the case 16 after passing through the air pump 12 and enters the second port 162, to pressurize the inside of the piping system 6. At this point, the wall 163 of the case 16 that faces the exhaust opening portion 137 and the hole 164 that is provided in the wall 163 correspond to the partition plate 139 and hole 138 in Embodiment 1, respectively. That is, similarly to the partition plate 139 and the hole 138, a space R2 that is separated from the outside of the third housing 132 by the wall 163 is formed on the downstream side of the check valve 121, and the noise generated by the vibration of the check valve 121 is reduced in the space R2.
As described above, according to Embodiment 2, the inside and outside of the third housing 132 of the air pump 12 are separated from each other with the wall 163 of the case 16 of the module 15 in which the electromagneitc valve 11 and air pump 12 are integrated with each other, so that the space R2 is formed on the downstream side of the check valve 121. Since the noise generated by the vibration of the check valve 121 is reduced in the space R2, similarly to Embodiment 1, it is possible to reduce the noise generated from the check valve 121 of the air pump 12 during the leak diagnosis.
In addition, in Embodiment 1, the noise countermeasure has been taken by additionally disposing the partition plate 139 that is the component for the noise countermeasure, but the noise countermeasure can be taken by utilizing the shape of the case 16 in Embodiment 2, and hence it is not necessary to additionally dispose the component for the noise countermeasure intentionally.
Embodiment 2 has described the case where the noise countermesure is taken by utilizing the shape of the case 16 when the electromagnetic valve 11 and air pump 12 are integrated into the module 15, and the noise countermeasure may be taken by utilizing the shape of another component such as a pipe when the air pump 12 is singly mounted to another component such as the pipe.
The intake opening portion 129 of the air pump 12 faces the opening portion 22 of the canister 2, and the exhaust opening portion 137 is covered with a filter 145 instead of the partition plate 139 shown in
During the leak diagnosis, the air pump 12 sucks the air having passed through the opening portion 22 of the canister 2 from the intake opening portion 129.
The air sucked from the intake opening portion 129 passes through the filter 145 and the hole 23 of the partition wall 24 after passing through the air pump 12 and enters the canister 2, to pressurize the inside of the piping system 6. At this point, the partition wall 24 that faces the exhaust opening portion 137 and the hole 23 that is provided in the partition wall 24 correspond to the partition plate 139 and the hole 138 in Embodiment 1, respectively. That is, similarly to the partition plate 139 and the hole 138, a space R3 that is separated from the outside of the third housing 132 by the partition wall 24 is formed on the downstream side of the check valve 121, and the noise generated by the vibration of the check valve 121 is reduced in the space R3.
As described above, according to Embodiment 3, the inside and outside of the third housing 132 of the air pump 12 are separated from each other with the partition wall 24 provided on the bottom surface of the insertion opening 21 prepared in the canister 2, so that the space R3 is formed on the downstream side of the check valve 121. Since the noise generated by the vibration of the check valve 121 is reduced in the space R3, similarly to Embodiment 1, it is possible to reduce the noise generated from the check valve 121 of the air pump 12 during the leak diagnosis.
The noise countermeasure has been taken by additionally disposing the partition plate 139 that is the component for the noise countermeasure in Embodiment 1, while in Embodiment 3, it is possible to mold the partition wall 24 and the hole 23 integrally when the canister 2 is molded, and hence it is not necessary to especially produce another member such as the partition plate 139, and it is possible to reduce the number of steps and time required for component production and assembly.
Similarly to the configurations shown in
In addition, also in the case where the air pump 12 shown in
Note that it is possible to freely combine the embodiments, modify any components of the embodiments, or omit any components in the embodiments within the scope of the invention of the present application.
Moreover, though the description has been made based on the assumption that the air pump 12 pressurizes the inside of the piping system 6 during the leak diagnosis, the leak diagnosis may be performed by depressurizing the inside of the piping system 6 with the air pump 12.
For example, in the case of the air pump 12 shown in
Further, the air pump 12 may also be, e.g., a turbine-type air one other than the vane-type one, and the check valve 121 may also be, e.g., a spherical ball valve other than the umbrella-shaped one.
As described above, since the air pump according to the invention is capable of reducing the noise generated from the check valve during driving, the air pump is suitably used as a component of an air pump-type leak diagnosis apparatus.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2014/061178 | 4/21/2014 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2015/162668 | 10/29/2015 | WO | A |
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| 20080230307 | Matsumoto et al. | Sep 2008 | A1 |
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| Number | Date | Country | |
|---|---|---|---|
| 20170107951 A1 | Apr 2017 | US |
