This invention relates generally to a carburetor and more particularly to a fuel flow adjustment assembly of a carburetor for a combustion engine.
As shown in
Because of machining tolerances and limitations during manufacture, fuel adjustment assemblies of this type include enough clearance between the threads of shank 23 of the needle valve 17 and the valve receptacle 18 to allow for lateral and axial movement of the tip 21 relative to the needle seat orifice when force is applied to the valve head 22. This lateral and axial movement can change the size of the orifice flow area enough to result in fuel flow rate changes of up to 20% from an optimum fuel flow rate determined by the manufacturer. Fuel flow rate changes caused by this needle “slop or wobble” result in excessively rich or lean fuel mixtures that undesirably increase exhaust emissions or affect engine performance. Therefore, it is desirable to reduce fuel flow fluctuations through the needle valve 17 and the resulting increase in exhaust emissions and/or deterioration of engine performance by limiting needle slop and wobble.
Not only is it desirable to limit or hold steady the lateral and axial position of the needle valve tip 21 with respect to the orifice and regardless of the valve's rotational position, it is also desirable to maintain the desired setting of the fuel flow in a running engine. Any inadvertent rotation of the needle valve 17, possibly caused by the vibration of a running engine or placement of a conventional limiter cap 25 over the valve's head 22 and after valve adjustments, can alter desired setting of the fuel flow. Therefore it is desirable to restrain the rotation of the needle valve 17 thereby preventing any unintended changes to the fuel flow setting. To do so, traditionally, compression springs 26 are disposed concentrically about the shank 23 and axially between the carburetor body 19 and the head 22 of the needle valve 17. The spring-induced axial force produces increased frictional forces amongst the threads between the carburetor body 19 and the needle valve 17, thus resisting needle valve rotation and alteration of the fuel flow setting. Unfortunately, springs 26 are relatively expensive to manufacture, and to produce sufficient frictional forces must be relatively long, causing the needle valves 17 to project a substantial distance outward from an otherwise compact carburetor.
One example of a stabilizing system for a fuel adjustment assembly is disclosed in U.S. Pat. No. 6,540,212, issued Apr. 1, 2003, assigned to Walbro Corporation, and incorporated herein by reference. This U.S. patent generally describes the carburetor fuel adjustment assembly 16 illustrated in
Another example of a stabilizing system for a fuel adjustment assembly is disclosed in U.S. Pat. No. 5,948,325, issued Sep. 7, 1999, assigned to U.S.A. Zama, Incorporated, and incorporated herein by reference. In this U.S. patent, a resilient fastening member is press fitted into a pre-drilled bore of a carburetor body. Once located in the bore, two needle valve receptacle cavities are bored transversely into the body and completely through the fastening member, thus the fastening member has a diameter which is larger than the receptacle cavity. Threads are then formed in the receptacles by rolling threads into both the carburetor body and the fastening member, for threadable receipt of the needle valves. Because the fastening member is resilient, it does not undergo plastic deformation during thread rolling and does not form actual female threads as does the metal portion of the receptacle or carburetor body. When the needle valves are installed and adjusted, the fastening member produces a frictional force upon the male threaded valve shanks which assuredly holds the valves in their adjusted position. Unfortunately, manufacture of the fastening member is expensive because after installation into the carburetor body, it must be drilled to produce two axially spaced through-holes and the threads must be formed by the thread rolling. Moreover, the process of manufacturing the carburetor is restricted because both the receptacles and the fastening member must be machined simultaneously. Yet further, the bore required to receive the fastening member is relatively long because the through-holes, and thus the receptacles, are spaced radically away from one-another and with respect to the longitude of the bore. This requires a large portion of the carburetor body to be dedicated for the bore and fastening members, and which might otherwise be utilized for other carburetor features, producing a relatively larger and less compact carburetor.
A carburetor fuel adjustment assembly includes one and preferably two needle valves threaded into respective receptacles of a carburetor body and engaged with a retainer of resilient material. Each receptacle defines an elongated cavity which intersects a fuel passage. Each needle valve has a shank which threadably engages its associated receptacle and a tip axially movable relative to an orifice or seat by rotation of the shank to control fuel flow. The resilient retainer body frictionally engages and laterally biases the needle valve into a steadfast position relative to the orifice or seat. This assures the adjusted or set fuel flow does not change by resisting unintended needle valve movement due to such factors as engine vibration and factory installation of limiter caps, and until an intentional and sufficient torque is applied to the needle valve to change its setting or adjusted position.
The resilient retainer may be in the form of a plug or sleeve and preferably, is inserted into a bore after the receptacles are machined. Preferably the bore extends between and is preferably transverse to a pair of receptacles and in part opens into the receptacles. In this way, a portion of the plug or sleeve is exposed in each receptacle with a convex or cylindrical shape. Because such exposures are preferably substantially equal, the torque required to rotate each of the needle valves are substantially the same for both needle valves.
Objects, features and advantages of this invention include a carburetor fuel flow adjustment assembly which prevents inadvertent alteration of fuel flow after calibration, after factory installation of limiter caps and/or during user operation, improves engine control, improves engine performance and useful life, provides a compact carburetor design, reduces manufacturing costs and assembly costs, is relatively simple design, robust, inexpensive, requires little to no maintenance and in service has a long useful life.
These and other objects, features and advantages of the invention will become apparent from the following detailed description of the preferred embodiment(s) and best mode, appended claims, and accompanying drawings in which:
Referring in more detail to the drawings,
The low and high-speed needle valves 44, 46 each preferably have a supplemental compression spring 64 which provides resistance against unintentional rotation of the needle valves 44, 46. The supplemental spring 64 generally concentrically encircles the shank 66 of the needle valve 44, 46 and is compressed axially between the radially enlarged head 68 of the needle valve 44, 46 and the carburetor body 38. The axial force produced by the compression springs 64 provides resistance which restrains rotation of the needle valves 44, 46 by indirectly creating friction between the male and female threads 70, 72 of the shanks 66 and the receptacles 40, 42 within the cavities 52, 54. In contrast, the resilient retainer 32 adds to this resistance by creating friction directly between itself and preferably the male threads 70 of the shank 66 and laterally urging the threads 70 into engagement with the female threads 72 in the carburetor body 34. Without use of the retainer plug 32, the size of the compression spring would be considerably larger to create the same frictional force. In many applications, elimination of the spring may be preferred. Preferably, a resilient annular seal 76 is fitted sealably between the needle 62 and the respective receptacles 40, 42 in a counter bore 78 of the cavity 52, 54.
The retainer may be in the form of a sleeve of a resilient plastic material located in a bore 82 of the carburetor body 38 having a centerline 84 which is substantially transverse and preferably perpendicular to and centered between the rotation axis 48, 50 of the low and high-speed needle valves 44, 46 (shown in
As best shown in
Empirical data has demonstrated that use of the retainer or sleeve 32 will reduce tip 62 wobble by many magnitudes compared to the annular seal 76 alone. Reducing tip 62 wobble or lateral shifting decreases the change in shape and flow area of an annular area 104 between the tip 62 and orifice 56 and thus decreases changes in the carburetor fuel flow characteristics (see
As best shown in
Customarily, the low and high-speed needle valves 44, 46 of the carburetor 34 are adjusted and set at the factory by the engine manufacturer after the carburetor body 38 is mounted to a running combustion engine, not shown. If the fuel-and-air mixture is too lean, the running engine may overheat causing warranty concerns. If the fuel-and-air mixture is too rich, government regulatory emission requirements may be exceeded or violated. Therefore, limiting adjustment capability by the end user of the engine of the low and high-speed needle vales 44, 46 within an acceptable range is desirable. The engagement of known limiter caps 74 to the heads 68 of the valves 44, 46 establishes the end user adjustment range for fuel flow within the carburetor (i.e. neither too rich nor too lean). The limiter caps 74 are typically press fitted over the heads 68 in the factory after the proper fuel flow settings are made. Without the retainer 32 and after factory adjustment by the engine manufacturer, the press fitting of the limiter caps 74 to the heads 68 of either one or both of the needle valves 44, 46 may move the needle valves 44, 46 axially and/or laterally, causing the factory setting and prescribed adjustment range of the needle valves to be altered or changed.
Empirical data has demonstrated that use of the retainer or sleeve 32 will reduce tip 62 wobble by many magnitudes compared to the annular seal 76 alone. Reducing tip 62 wobble or lateral shifting decreases the change in shape and flow area of an annular area 104 between the tip 62 and orifice 56 and thus decreases changes in the carburetor fuel flow characteristics (see
While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. For instance, the carburetor 34 may have only one needle valve. In this application the retainer 32 may be the solid embodiment as opposed to the sleeve for cost or other considerations. Yet further, it is conceivable that retainer 32 rather than bearing directly upon the male threads 70 of the shank 66, as illustrated, may also bear directly upon a smooth portion of the shank 66 which does not carry male threads. It is also conceivable that in many applications use of the spring 64 will not be required because the retainer will provide sufficient lateral force and axial restraint on the needle valves 44, 46 to prevent unintentional rotation. It is not intended herein to mention all the possible equivalent forms or ramifications of the invention. It is understood that the terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing form the spirit or scope of the invention.
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Number | Date | Country |
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55-104556 | Aug 1980 | JP |