The present invention relates to an adjustment device for adjusting the relative angular position of a camshaft with respect to a crankshaft within a specified adjustment angle range.
In an emergency, such as, for example, if faults occur in the electronics, the sensors or the actuators, adjustment devices or camshaft adjusters of this kind must bring the camshaft into a defined emergency running position (e.g., fail-safe position) to ensure that the internal combustion engine can continue to operate at least with limitations. In particular, the emergency running position can be chosen so that the internal combustion engine can also be started in this position.
Usually, i.e., in normal operation of the internal combustion engine, the camshaft is moved under control to its basic or emergency running position (for example, with the help of an adjustment motor) when the internal combustion engine is switched off, i.e., as a rule the “late” position in the case of an inlet camshaft or the “early” position in the case of an exhaust camshaft. If, however, the internal combustion engine stalls or the electronics (e.g., the adjustment motor) fails, the camshaft can be in an undefined position away from the emergency running position, which can lead to problems when the internal combustion engine is restarted.
Devices for adjusting the camshaft of an internal combustion engine are normally in the form of an adjustment gearbox, in particular a three-shaft gearbox, which, for example, has an input drive shaft connected to the crankshaft, an output drive shaft connected to the camshaft and an adjustment shaft connected to an electric adjustment motor.
An electromechanical phase adjuster for adjusting the phase position of a camshaft relative to a crankshaft of an internal combustion engine, with which the range of possible phase positions (adjustment angle range) of the camshaft is limited by two end stops, the so-called late end stop and the so-called early end stop, is disclosed in document WO 2005/008034.
In an embodiment, these two end stops are connected to a rotating disc of the gearbox which is connected to the camshaft gear and interact with a stop which is located on the gearbox output side on a rotating disc of the gearbox which is connected to the camshaft.
The gearbox of the electromechanical phase adjuster is not self-locking, i.e., a torque at its gearbox input side causes a rotation at its gearbox output side and vice versa.
Furthermore, the adjustment gearbox has a negative rotational transmission ratio, i.e., the direction of rotation at the gearbox input side associated with the adjustment drive is opposite to that at the gearbox output side. As a result of this, a retardation of the gearbox input side effects an adjustment of the gearbox output side in the “early” direction. If this fails, then a locking device causes the camshaft to move into a specified emergency running position. Depending on the design, the stop which is arranged on the camshaft or the two end stops which limit the adjustment angle range is/are designed to be movable for this purpose. For the purpose of repositioning, a pre-tensioned spring, which in normal operation is held in its pre-tensioned position by means of a latching mechanism, is provided on the stop to be moved. As a result of activating an unlocking mechanism of the locking device, the latching mechanism is released so that, due to its pre-tensioning, the spring can move the associated stop.
A blocking mechanism, which is likewise associated with the stop to be moved, prevents it moving in a direction which opposes the spring pre-tensioning. In an emergency situation in which the electric adjustment drive has failed, the unlocking mechanism, therefore, unlocks the latching mechanism so that the stop of the camshaft is brought into contact with the end stop of the input drive gear. The blocking mechanism prevents the possibility of the camshaft moving in opposition to the end stop which is in contact therewith.
When the phase adjustment direction is subsequently changed again, the first end stop or the stop which rests against the end stop is moved towards its emergency running position until it reaches this position. In the emergency running position, the second end stop also rests against the stop, and thus, locks the phase adjustment device in its emergency running position.
In accordance with this embodiment, a freely definable mid-position (position within the adjustment range) can be chosen as the emergency running position (fail-safe position). It is not disclosed, however, how the actuators used can leave the emergency running operating state (fail-safe mode) in order to change over to normal operation. This is, however, particularly important when, for example, it transpires that the emergency running mode has only been initiated as a result of a plausibility problem or a temporary fault.
Furthermore, a device for releasably connecting and adjusting the camshaft and the crankshaft of an internal combustion engine is disclosed in WO 03/095803 A1. Here, the emergency running position of the camshaft is achieved by rotating the drive shaft, which is connected to the crankshaft, and by a suitable stationary gear ratio. In this embodiment, the emergency running position is therefore achieved in that contact is made with a mechanical end stop. The emergency running position therefore corresponds to the maximum early or late setting on the respective early end stop or late end stop of the camshaft.
It can, however, transpire that the camshaft does not achieve its final emergency running position, especially when the adjustment motor produces a braking torque when it ails or when an actuating electronic device fails. Furthermore, a reliable positioning of the camshaft is not guaranteed, thus enabling it to leave its emergency running position, possibly in an uncontrolled manner. This can occur particularly as a result of the inertia-induced torques through the adjustment motor which the internal combustion engine produces at the gearbox input of the adjustment gearbox when accelerating or braking, or when strongly alternating torques act on the camshaft.
Furthermore, DE 10 2004 061 710 A1 discloses a camshaft adjustment device which, in an emergency, can be locked with the help of a locking element for locking a component fixed to the camshaft to a component fixed to the crankshaft.
Furthermore, an electric camshaft adjuster, in which a pre-tensioned spring pushes the camshaft adjuster back into an appropriate end position (maximum early position or maximum late position of the camshaft), is disclosed in WO 2011/104051 A1. The disadvantage of such an embodiment can be that the spring is not only active in emergency mode, but also positively acts on the camshaft over the whole adjustment range thereof, which may have a negative effect with regard to its energy consumption. If the spring force of this adjustment spring is chosen to be smaller, then there is a risk that its adjustment force is not sufficient to move the camshaft into the required end position in an emergency. Moreover, with this embodiment too, the camshaft can be moved out of its emergency running position in an uncontrolled manner in the event of particularly high strongly alternating torques.
Finally, DE 10 2004 033 522 A1 discloses a cam adjuster with electric drive, in which the adjustment device for adjusting the relative angular position of the camshaft with respect to the crankshaft has an adjustment drive as primary adjustment device and an auxiliary drive as secondary adjustment device. If the adjustment motor fails, the camshaft can be moved into a fixed angular position, the so-called emergency running position, by means of the auxiliary drive. A possible design of such an auxiliary drive includes a torsion spring which is pre-tensioned in a basic position by a displacement of the angle of rotation between the drive gear of the camshaft and part of the adjustment gearbox which is fixed to the camshaft and, in the event of a failure of the adjustment motor, effects a resetting by releasing the tension.
The disadvantage of this embodiment, however, is the costs associated with providing such an auxiliary drive. Further, the auxiliary drive requires a not insignificantly large proportion of the available installation space, which can likewise be seen as a disadvantage.
On the other hand, an object of the present invention is providing an adjustment device for adjusting the relative angular position of a camshaft with respect to a crankshaft, with which the disadvantages that have become known from the prior art can be at least partially reduced.
In accordance with the present invention, an adjustment device configured to adjust the relative angular position of a camshaft with respect to a crankshaft within a predetermined angle range, the adjustment device including at least one of the following: an emergency device including a freewheel device configured for activation in an emergency mode of the adjustment device to permit an adjustment movement of the camshaft with respect to the crankshaft from a first position in a first direction towards a second, emergency running position and to block an adjustment movement in a second direction opposite thereto, the emergency device including a locking device configured to lock the adjustment device when the camshaft has reached an emergency running position relative to the crankshaft and an actuator configured to activate the freewheel device.
In accordance with the present invention, an adjustment device configured to adjust the relative angular position of a camshaft with respect to a crankshaft within a predetermined angle range, the adjustment device including at least one of the following: an emergency device including a freewheel device configured for activation in an emergency mode of the adjustment device to permit an adjustment movement of the camshaft with respect to the crankshaft from a first position in a first direction towards a second, emergency running position and to block an adjustment movement in a second direction opposite thereto, the emergency device including a locking device configured to lock the adjustment device when the camshaft has reached an emergency running position relative to the crankshaft and an actuator configured to activate the freewheel device.
The adjustment device can be in the form of an adjustment gearbox, in particular a three-shaft gearbox, which is configured to adjust the relative angular position of the camshaft of an internal combustion engine with respect to its crankshaft. The device for emergency operation of the adjustment device (emergency running device) can, for example, be designed in the form of a switchable freewheel device which is not active in normal operation and is activated in emergency running mode. In its activated state, the freewheel device is designed to permit movement of the camshaft relative to the crankshaft in only one direction and to block it in the opposite direction. Furthermore, the movement of the camshaft in the one direction is permitted until an end stop or a predetermined emergency running position of the camshaft is reached.
When the device for emergency operation of the adjustment device is activated, the input drive of a camshaft drive gear (e.g., in the form of a chain wheel) with a non-uniform speed is used to move the camshaft into its emergency running position.
Furthermore, it can be provided that the freewheel device is securely connected to the camshaft.
Furthermore, the freewheel device can have an interlocking and/or frictional connection to a part of the adjustment device which rotates relative to the camshaft in order to block an adjustment movement of the camshaft with respect to the crankshaft in the second direction.
Here, an interlocking connection is understood to mean a connection in which one connection partner prevents the movement of the other connection partner, at least in one direction of movement, by resting against it. Furthermore, a connection is a frictional connection when the connection partners are connected to one another by static friction.
The freewheel device of the adjustment device in accordance with embodiments can include a spring pre-tensioned pawl which is designed to engage in an interlocking manner in a gear element of the adjustment device which is designed in the form of an adjustment gearbox.
The freewheel device preferably acts between an input drive gear or the gearbox output of an adjustment device, which is designed in the form of an adjustment gearbox, and a further gearbox part. The further gearbox part can be an element of the gearbox with a higher ratio, such as the gearbox input gear or a planet gear, for example. This enables the necessary forces which the freewheel device has to provide for the operation of the emergency running device to be significantly reduced so that, if necessary, the freewheel device can also be made of plastic.
Furthermore, in order to activate the device for emergency operation (emergency running device), the adjustment device in accordance with embodiments can include an actuator for activating the freewheel device. In particular, the actuator can include an end limit switch which is arranged outside the adjustment angle range of the camshaft relative to the crankshaft in normal operation of the adjustment device. This activates the emergency running device by reaching a defined phase angle of the camshaft which lies outside the angular range used in normal operation of the internal combustion engine. For example, the actuator can be provided at that end of the adjustment range towards which the adjustment device typically moves (when the adjustment motor fails).
In addition to the actuator, a mechanical end stop, which is arranged at this end of the adjustment range to further safeguard the adjustment range, can also be provided in accordance with embodiments.
Consequently, in such an embodiment, the emergency running device can be activated at one end of the adjustment range. The freewheel device then moves the camshaft away from this end towards the other end of the adjustment range until an emergency running position of the camshaft or the other end stop is reached.
Furthermore, the device for emergency operation of the adjustment device (emergency running device) in accordance with embodiments can include a locking device configured to lock the adjustment device when the camshaft has reached its emergency running position relative to the crankshaft. The locking device therefore constitutes a blocking device or inhibiting device which, on reaching a particular predefined adjustment angle of the camshaft, locks the adjustment gearbox or adjustment device and inhibits further adjustment at least up to a pre-specified torque. For example, such a torque can be rated so that this torque is not reached when an adjustment motor is de-energized and therefore the adjustment device remains in this position during further operation (emergency running mode) of the internal combustion engine. On the other hand, when the adjustment motor is activated once more, the pre-specified torque can be exceeded thereby, so that with the help of the adjustment motor the camshaft can be moved beyond this angular position in the direction allowed by the freewheel device until the appropriate end stop is reached.
Furthermore, the locking device in accordance with embodiments can also have a different behavior in its activated state depending on the speed or depending on the direction. In particular, the locking device can be designed so that, at a camshaft speed which is less than a specified threshold value, it releases the adjustment device on reaching the respective phase angle of the adjustment device, and, above a camshaft speed which is greater than the threshold value, it blocks the adjustment device. Also, the torque necessary for further movement of the adjustment device (the threshold value) can become smaller or larger or approximately zero with increasing camshaft speed due to the activated locking device. Such a speed dependency can be achieved particularly easily by utilizing the speed-dependent centrifugal force which acts on the parts attached to the adjustment device.
Furthermore, the locking device in accordance with embodiments can include a locking bolt which is set up to act between the input drive gear of the camshaft and a part which is fixed to the camshaft.
Furthermore, the locking device in accordance with embodiments can include an elastic element, in particular a leaf spring, which is able to pre-tension the locking bolt in the direction of its locking position.
Basically, both the freewheel device and the locking device can be deactivated once more by an appropriate actuator. For example, this can be the same actuator which activates the freewheel device and/or the locking device. Alternatively however, it can also be a different actuator, i.e. a first actuator can be provided for activating the freewheel device and/or the locking device, and a second actuator can be provided for deactivating the freewheel device and/or the locking device.
Alternatively, instead of an (active) actuator for deactivating the freewheel device and/or the locking device, resetting or deactivation can also be effected on reaching an end stop, so that the adjustment device works in normal operation once more when this end stop has been reached.
It can be provided that the freewheel device and the locking device in accordance with embodiments are designed integrally with one another. In such a case, a single component, in which the two functions of freewheel device and locking device are incorporated, is provided.
Accordingly, it can also be provided that the actuator is provided for activating both the freewheel device and the locking device and for deactivating both the freewheel device and the locking device.
Regardless of the type of activation of the freewheel device, it can also be provided that this is activated and deactivated depending on the speed.
In accordance with embodiments, advantageously, the freewheel device also includes a rocker arm to which a pawl of the freewheel device is attached in such a way that it can swivel. The rocker arm can be mounted rotatably or pliably in a pivot point on the base plate or on the input drive gear of the adjustment device and then oscillate or pivot about this pivot point when it is unlocked. One or more spring elements, which are designed to hold the rocker arm in a nominal position (zero position) about which the rocker arm can oscillate, can also be provided. For example, the spring elements can be in the form of springs and be supported on the base plate or input drive gear of the adjustment device.
At a particular camshaft speed or a particular frequency excitation of the speed non-uniformity of the camshaft drive, and when the rocker arm is unlocked, the arm oscillates to an increasing extent about its nominal position until the attached pawl turns the gearbox input gear wheel, for example, further by one tooth. In doing so, the spring elements serve to match the inertia of the rocker arm for a required resonant frequency.
This is advantageous particularly when a movement of the adjustment drive or of the adjustment device towards the emergency running position is not possible without such a rocker arm, as driving the gearbox input gear wheel, for example, would require too great a force.
The freewheel device in accordance with embodiments can also include a further pawl which is suitable for engaging in an interlocking manner in a gear element of the adjustment gearbox of the adjustment device.
Alternatively or additionally to the rocker arm described above, a linearly moved oscillator can be used, the mass of which likewise oscillates in a substantially tangential direction when the adjustment gearbox is activated.
Embodiments of the invention is described below with reference to the attached figures which show embodiments of the invention by way of example. Schematically, in the drawings:
a and 3b illustrate the device for emergency operation of the adjustment device in an isometric rear view, in
a, 4b and 4c illustrate the adjustment device of
The adjustment device 10 also includes an emergency running device 20 which is connected in a rotationally fixed manner to the base plate 18 and, in
The emergency running device 20, or an integral component of the device 20 for emergency operation of the adjustment device 10, is illustrated in detail in
As well as the component illustrated in
The component of the emergency running device 20 illustrated in
The freewheel device 22 includes a pawl 32, which at its free end has a catch or latch 40, which in an assembled state projects towards the gearbox input gear 16. The locking device 24 includes a leaf spring 34, which is formed on the component of the emergency running device 20 illustrated in
A projection 42, under which a corresponding holding projection 36 engages as long as the freewheel device is deactivated, i.e. the adjustment device is running in normal mode (cf.
A locking projection 46 for the locking bolt 50 in normal operation is provided opposite the free end of the leaf spring 34. This engages (as can be seen by way of example in
Furthermore, it can be seen in
The principle of operation of the present invention is described in more detail below with reference to
The adjustment gearbox of the adjustment device 10 shown is a positive gearbox or positive summing gearbox with a positive step-up/step-down ratio, with which the camshaft rotates in the direction indicated by the arrow designated by D. In normal operation, the adjustment motor on the gearbox input gear 16 ensures that the camshaft rotates in a defined phase position with respect to the chain wheel 12. If the adjustment motor fails, for example, then it produces an appropriate braking torque and its speed falls compared with the chain wheel or camshaft drive gear 12. As a result, commensurate with the positive gearbox, the camshaft is reversed, that is to say moved in the “late” direction, i.e. the angle Xa between a stop 54 of the base plate 18 and a stop 48 of the chain wheel 12 is reduced to an angle Xb (cf.
In doing so, the camshaft is moved beyond the maximum late position in normal operation until the actuator in the form of release lever 26 is tripped. As can be seen in
The release lever 26 is attached to the emergency running device 20 via an elastic intermediate region 38 of the release lever 26, which at the same time acts in the manner of a hinge point.
The freewheel device 22 is activated due to the slight displacement of the stop 30 of the release lever 26 together with the holding projection 36 and the locking projection 46. The projection 42 of the pawl 32, therefore, releases from the holding projection 36 and, as a result of its elastic pre-tensioning towards the gearbox input gear 16, is displaced radially inwards until the latch or catch 40 engages in the external gearing of the gearbox input gear wheel 16. From now on, as long as the adjustment device 10 is in emergency running mode, the activated freewheel device 22 only allows a forwards movement (in direction of rotation D of the camshaft) of the gearbox input gear wheel 16 with respect to the part, the base plate 18, which is fixed to the camshaft.
As the drive to the camshaft via the camshaft drive gear or chain wheel 12 is non-uniform even in steady-state operation of the internal combustion engine, angular ranges in which the camshaft drive gear or chain wheel 12 is accelerated and angular ranges in which it is decelerated repeatedly occur. In this way, the gearbox input gear wheel 16 together with a rotor of the inactive adjustment motor is also accelerated by the activated freewheel device in the acceleration phase, i.e., the freewheel device takes the gearbox input gear 16 of the adjustment motor with it. In the subsequent deceleration phase of the chain wheel 12, the rotational pulse of the adjustment motor and of the gearbox input gear wheel 16 is sufficiently large to move the gearbox input gear wheel 16 forwards by a small amount with respect to the base plate 18 (i.e., in the direction of rotation D of the camshaft) against any braking torque of the inactive adjustment motor which may be acting. In this way, the camshaft is moved in the direction of its emergency running position.
When this is reached (cf.
After the chain wheel 12 has been blocked relative to the base plate 18 with the help of the locking bolt 50, the adjustment device can be pre-tensioned approximately free from play or even totally free from play by a small further forwards movement of the gearbox input gear wheel 16 with respect to the part fixed to the camshaft, i.e. the base plate 18.
Finally, a further embodiment of the freewheel device, which in
In the embodiment shown in
The remaining components of the adjustment device are omitted in order to simplify the view. However, the rocker arm 160 is likewise rotatably flexibly mounted with respect to a pivot point 166 on the base plate (not shown in
The spring elements 156 can likewise be supported by their other end in each case, for example on the base plate of the adjustment device. The rocker arm 160 is held in a nominal angular position and can also be locked by the two spring elements 156. In emergency mode or emergency running of the locking device, such a lock is then released, and at a certain speed excitation of the camshaft drive the arm resonates and thus produces a particularly high force in order to move the camshaft towards the emergency position. At the same time, the resonant frequency can be adjusted by way of the spring elements 156, such that these can be designed so that said frequency is reached during the engine start-up of the internal combustion engine, i.e., by the starter of the internal combustion engine.
Although embodiments have been described herein, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the all that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
The present application claims priority under 35 U.S.C. §119 to U.S. Provisional Patent Application No. 61/481,339 (filed on May 2, 2011), which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
---|---|---|---|
61481339 | May 2011 | US |