Patent Grant
8868316
The present invention relates to a controller of a valve timing control apparatus configured to variably control valve open timing and valve closure timing of each of engine valves, such as intake and/or exhaust valves, by the use of an electric motor, and specifically to an electric-motor-driven valve timing control apparatus of an internal combustion engine.
In recent years, there have been proposed and developed various electric-motor-driven valve timing control devices in which rotary motion (a torque) of an electric motor is transmitted via a speed reducer to a camshaft so as to change a relative angular phase between the engine crankshaft and the camshaft with the high control responsiveness and high controllability. One such electric-motor-driven valve timing control device has been disclosed in Japanese Patent Provisional Publication No. 2010-138735 (hereinafter is referred to as “JP2010-138735”). In the valve timing control device disclosed in JP2010-138735, by virtue of electric-current supply via spring-loaded brushes and slip rings to an electric motor, the motor is rotated. The rotary motion of the electric motor is transmitted via a speed reducer to a camshaft, and as a result an angular phase of the camshaft relative to the crankshaft is changed to control engine valve timing, such as intake valve timing.
However, the valve timing control device disclosed in JP2010-138735, suffers from the drawback that, when initiating relative-phase control between the crankshaft and the camshaft during an engine starting period, in particular, when starting with a cold engine, an electric motor is driven from its stopped state and thus a time loss occurs owing to a static friction before the electric motor actually begins to rotate and hence undesirable hunting of the automatic phase control system occurs. As a result of such undesirable hunting, a control state of the phase control system tends to become unstable immediately after the electric motor has been driven. Therefore, it would be desirable to reconcile both a phase-change control responsiveness and a phase-change control stability without undesirable hunting, even during an engine starting period.
It is, therefore, in view of the previously-described disadvantages of the prior art, an object of the invention to provide a controller of a valve timing control apparatus and a valve timing control apparatus of an internal combustion engine, capable of reconciling both a control responsiveness and a control stability of an electric-motor-driven phase-change control system even during an engine starting period.
In order to accomplish the aforementioned and other objects of the present invention, a controller of a valve timing control apparatus including a drive rotary member adapted to rotate in synchronism with rotation of a crankshaft of an engine, an electric motor which rotates together with the drive rotary member and to which electric current is supplied via brushes, and a phase converter configured to change a phase angle of a camshaft relative to the crankshaft by relatively rotating an output shaft of the electric motor with respect to the drive rotary member, said controller comprises a detection section configured to detect a rotational position of the camshaft, and a control section programmed to perform the following,
(a) executing phase-control via the phase converter for bringing the phase angle of the camshaft relative to the crankshaft closer to a required phase angle suited for engine-starting during a starting period of the engine;
(b) controlling the phase angle of the camshaft during a stopping period of the engine to a target phase angle differing from the required phase angle suited for engine-starting;
(c) changing the phase angle of the camshaft from the target phase angle toward the required phase angle during a time period from a point of time when cranking starts during a restarting period of the engine to a point of time when detection of the rotational position of the camshaft, executed within the detection section, initiates during the engine restarting period; and
(d) starting feedback-control for the phase angle of the camshaft via the phase converter from the point of time of initiation of detection of the rotational position of the camshaft, executed within the detection section, for bringing the phase angle of the camshaft closer to the required phase angle.
According to another aspect of the invention, a controller of a valve timing control apparatus including a drive rotary member adapted to rotate in synchronism with rotation of a crankshaft of an engine, an electric motor which rotates together with the drive rotary member and to which electric current is supplied via brushes, and a phase converter configured to change a phase angle of a camshaft relative to the crankshaft by relatively rotating an output shaft of the electric motor with respect to the drive rotary member, said controller comprises a detection section configured to detect a rotational position of the camshaft, and a control section programmed to perform the following,
starting phase-control, by which the phase angle of the camshaft can be brought closer to a required phase angle suited for engine-starting via the phase converter by feeding back a result of detection of the detection section, continuously from a state where the electric motor has already rotated during a starting period of the engine.
According to a further aspect of the invention, a valve timing control apparatus of an internal combustion engine comprises a drive rotary member adapted to rotate in synchronism with rotation of a crankshaft of the engine, an electric motor which rotates together with the drive rotary member and to which electric current is supplied via brushes, a phase converter configured to change a phase angle of a camshaft relative to the crankshaft by relatively rotating an output shaft of the electric motor with respect to the drive rotary member, a phase angle detector configured to detect a rotational position of the camshaft, and a controller comprising a processor programmed to perform the following,
(a) executing phase-control via the phase converter for bringing the phase angle of the camshaft relative to the crankshaft closer to a required phase angle suited for engine-starting during a starting period of the engine;
(b) stopping the phase converter at a target phase angle differing from the required phase angle during a stopping period of the engine; and
(c) starting feedback-control, by which the phase angle of the camshaft can be brought closer to the required phase angle by feeding back a result of detection of the phase angle detector, in a manner so as to drive the electric motor in the same direction of rotation of the electric motor continuously from a state where the electric motor has already rotated after initiation of cranking during a restarting period of the engine.
The other objects and features of this invention will become understood from the following description with reference to the accompanying drawings.
A valve timing control (VTC) apparatus of an internal combustion engine of the embodiment and its controller are hereinafter described in detail in reference to the drawings. In the shown embodiment, the VTC apparatus is applied to a valve operating system of the intake-valve side of the internal combustion engine. In lieu thereof, the VTC apparatus may be applied to a valve operating system of the exhaust-valve side of the engine
As shown in
Timing sprocket 1 is comprised of an annular sprocket body 1a, and a timing gear 1b. Sprocket body 1a is made of iron-based metal material, and formed with a stepped inner peripheral portion and formed integral with timing gear 1b. Timing gear 1b receives torque from the crankshaft through a timing chain (not shown) wound on both a sprocket on the crankshaft and the sprocket 1 on the camshaft. Timing sprocket 1 is rotatably supported by a middle-diameter ball bearing 43 interleaved between a circular groove 1c formed in sprocket body 1a and the outer periphery of a thick-wall flanged portion 2a integrally formed with the front end of camshaft 2.
Sprocket body 1a has an axially-protruding annular edged portion 1d formed integral with the outer periphery of its front end. As shown in
As clearly shown in
Sprocket body 1a and annular member 19 construct a casing of a speed reducer 8 (described later).
The outside diameters of axially-protruding annular edged portion 1d of sprocket body 1a, annular member 19, and female-screw-threaded annular portion 6 are dimensioned to be substantially identical to each other.
Additionally, as best seen in
Cover member 3 is formed as a substantially cup-shaped integral cover, which is made of aluminum alloy. Cover member 3 is comprised of a substantially cup-shaped cover main portion 3a and an axially-extending cylindrical wall portion 3b partly formed integral with the outer peripheral portion of cover main portion 3a. Cover main body 3a is laid out to cover almost the entire circumference of the front end of housing 5, ranging from the leftmost end (viewing
As shown in
As shown in
Housing 5 is made of iron-based metal material, and comprised of a cylindrical housing main body 5a and a disk-shaped housing bottom portion 5b integrally formed at the rear end of housing 5 with the housing main body 5a by press molding, and a substantially annular seal plate 11 provided to seal the front-end opening of housing main body 5a. Housing bottom portion 5b is formed at its center with a large-diameter shaft insertion hole 5c into which a substantially cylindrical-hollow eccentric shaft portion 39 (described later) is inserted. Housing bottom portion 5b is also formed with a cylindrical portion 5d slightly axially extending leftwards from the front end of shaft insertion hole 5c. The previously-discussed female-screw-threaded annular portion 6 is integrally formed with the circumference of housing bottom portion 5b.
Camshaft 2 has two drive cams (per cylinder) integrally formed on its outer periphery for operating the associated two intake valves (not shown) per one engine cylinder. A driven member (a driven rotary member) 9 is fixedly connected to the front end of camshaft 2 by means of a cam bolt 10. As shown in
As best seen in
Driven member 9 is made of iron-based metal material. As seen from the longitudinal cross section of
The disk-shaped portion 9a is integrally formed on the central portion of its rear end face with an annular stepped portion 9c. The outer periphery of annular stepped portion 9c and the outer periphery of flanged portion 2a are assembled to be opposed to each other, and additionally the annular stepped portion 9c of driven member 9 and the flanged portion 2a of camshaft 2 are fitted to the inner periphery of the inner race 43a of the middle-diameter ball bearing 43. Hereby, when assembling, the axis of camshaft 2 and the axis of driven member 9 can be easily precisely aligned with each other. On the other hand, the outer race 43b of the middle-diameter ball bearing 43 is press-fitted to the inner periphery of circular groove 1c of sprocket body 1a.
As shown in
As shown in
The previously-discussed phase converter 4 is constructed by the electric motor 12, serving as an actuator and located at the front end of camshaft 2 and arranged coaxial with the axis of camshaft 2, and the speed reducer 8. Speed reducer 8 is provided to reduce the rotational speed of the output shaft 13 of electric motor 12 and to transmit the reduced rotational speed (in other words, the increased torque) to camshaft 2.
As shown in
Motor output shaft 13 is formed into a substantially cylindrical-hollow shape, and serves as an armature. An iron-core rotor 17, having a plurality of magnetic poles, is fixedly connected onto the outer periphery of motor output shaft 13 substantially at a midpoint of the axially-extending cylindrical-hollow motor output shaft 13. An electromagnetic coil 18 is wound on the outer periphery of the iron-core rotor 17. A commutator 20 is press-fitted onto the outer periphery of the small-diameter portion of the front end of the cylindrical-hollow motor output shaft 13. Commutator 20 is divided into a plurality of segments whose number is equal to the number of magnetic poles of iron-core rotor 17. Electromagnetic coil 18 is electrically connected to each of the segments of commutator 20.
As shown in
Seal plate 11 is positioned and fitted to the stepped recessed groove formed in the inner periphery of the front end of the cylindrical housing main body 5a by means of a snap ring 55. Seal plate 11 has a central bore (a central opening) through which one end of motor output shaft 13 is inserted.
Brush retainer 28, integrally molded and produced by synthetic resin, is attached to the cover main portion 3a.
As shown in
These two terminal strips 31, 31 are arranged parallel to each other in such a manner as to vertically extend and partly cranked. One end (the lower terminal) 31a of each terminal strip 31 is laid out to be exposed onto the bottom face of brush retaining portion 28a, whereas the other end (the upper terminal) 31b of each terminal strip 31 is laid out to protrude into a female fitted groove 28d of connector portion 28b. Each upper terminal 31b is electrically connected via a male terminal (not shown) to a car battery (an electric-power source).
Brush retaining portion 28a has an upper sleeve 29a, fitted into a cylindrical through hole formed in brush retaining portion 28a and extending in the axial direction of the camshaft, and a lower sleeve 29b, fitted into a cylindrical through hole formed in brush retaining portion 28a and extending in the axial direction of the camshaft. A pair of second brushes 30a-30b are axially slidably fitted into the respective sleeves 29a-29b. To ensure electric-contact (sliding-contact), the second brushes 30a-30b are axially permanently spring-loaded toward the outer periphery of the respective slip rings 26a-26b.
Each of second brushes 30a-30b is shaped into a substantially rectangular parallelepiped shape. A second coil spring 32a is interleaved between the lower terminal 31a located on the bottom face of the upper cylindrical through hole formed in brush retaining portion 28a and the second brush 30a, so as to force the second brush 30a into electric-contact with the slip ring 26b. In a similar manner, a second coil spring 32b is interleaved between the lower terminal 31a located on the bottom face of the lower cylindrical through hole formed in brush retaining portion 28a and the second brush 30b, so as to force the second brush 30b into electric-contact with the slip ring 26a. Also, the inside axial end (the left-hand axial end, viewing
An annular seal member 34 is fitted into a substantially annular groove 35 (see
For the purpose of both good elastic contact between the second brushes 30a-30b with the respective slip rings 26a-26b and avoidance of falling of the second brushes 30a-30b from the respective sleeves 26a-26b, a length L between (i) the outside axial end face (the right-hand axial end, viewing
The upper terminals 31b of connector portion 28b are electrically connected via the male terminal (not shown), fitted to the female fitted groove 28d, to a control unit 40, serving as an electronic control unit (ECU).
Referring now to
Returning to
As shown in
A small-diameter oil seal 46 (a relatively small-diameter seal ring) is interleaved between the outer peripheral surface of motor output shaft 13 (in close proximity to the eccentric shaft portion 39) and the inner peripheral surface of the axially-extending cylindrical portion 5d of housing 5, for preventing leakage of lubricating oil from the inside of speed reducer 8 toward the electric motor 12. The oil seal 46 is a typical spring-loaded, synthetic-rubber-covered seal ring consisting of a single lip using a spring, a metal case and a dust lip using no spring. The inner peripheral portion of the oil seal 46 is kept in elastic-contact and in sliding-contact with the outer peripheral surface of the cylindrical-hollow motor output shaft 13, so as to apply a frictional resistance to rotation of motor output shaft 13.
As shown in
Also, control unit 40 is also configured to set or compute a required phase angle of camshaft 2 relative to timing sprocket 1 (i.e., the engine crankshaft), based on the current engine operating condition (e.g., engine speed and engine load) and a feedback signal from phase-angle detection means provided for detecting the current rotational position of camshaft 2. Control unit 40 is further configured to perform, based on the computed required phase angle, normal-rotation/reverse-rotation control of motor output shaft 13 by controlling electric-current supply to electromagnetic coil 18 of electric motor 12, while reducing the rotational speed of motor output shaft 13 by means of speed reducer 8. In this manner, the actual relative angular phase of camshaft 2 to timing sprocket 1 can be controlled based on the computed required phase angle.
The previously-noted phase-angle detection means is comprised of an angular position sensor (e.g., a camshaft position sensor or a motor-output-shaft position sensor) for detecting a rotational position of camshaft 2 in the form of a pulse signal, and an arithmetic circuit (a phase-angle detector or a detection section) included in control unit 40 for arithmetically calculating, based on the pulse signal from the angular position sensor, the current rotational position of camshaft 2. With the previously-discussed arrangement of the phase-angle detection means, it is possible to enhance the accuracy of detection of the rotational position of camshaft 2.
As described later, control unit 40 is also configured to perform rotation control of electric motor 12 responsively to an engine temperature (e.g., an engine coolant temperature Tw) during a time period from a point of time when the engine is stopped to a point of time when the engine is started/restarted. By this, during the engine stopped period, the phase angle of camshaft 2 relative to timing sprocket 1 (i.e., the crankshaft) can be controlled or phase-changed to a phase angle differing from the computed required phase angle in advance. In contrast, during an engine starting period having the difficulty of detecting the phase angle of camshaft 2 relative to timing sprocket 1, in other words, in an undetected state of the phase angle of camshaft 2 relative to timing sprocket 1 during the early stages of engine starting, a given operating force is applied via phase converter 4 to camshaft 2 or there is no application of operating force via phase converter 4 to camshaft 2, and thereafter feedback (F/B) control for the phase angle of camshaft 2 restarts from a point of time when phase-angle detection of camshaft 2 relative to timing sprocket 1 (that is, detection of the rotational position of camshaft 2), executable within control unit 40, initiates or restarts.
As seen from the cross sections of
Eccentric shaft portion 39 is a substantially cylindrical cam whose geometric center “Y” (see
Large-diameter ball bearing 47 is formed as a relatively large-diameter ball bearing, as compared to the middle-diameter ball bearing 43 and the small-diameter ball bearing 37. As viewed from the longitudinal cross section of
Owing to the eccentric displacement (oscillating motion) of large-diameter ball bearing 47, the radially-inward contact surface of each of rollers 48, included within a given area, is brought into abutment (rolling-contact) with the outer peripheral surface of the outer race 47b of large-diameter ball bearing 47. On the other hand, the radially-outward contact surfaces of some of rollers 48, associated with the given area, are fitted into some troughs of internal teeth 19a of annular member 19. More concretely, in the eccentric position of the eccentric rotation member (namely, large-diameter ball bearing 47 and eccentric shaft portion 39) shown in
To ensure smooth operation of the motor-driven phase-converter equipped VTC apparatus, lubricating oil is supplied into the interior space of speed reducer 8 by lubricating-oil supply/exhaust means. The lubricating-oil supply/exhaust means is comprised of an oil supply passage (not shown) formed in the camshaft-journal bearing of the cylinder head for lubricating-oil supply from a main oil gallery (not shown), an axial oil supply hole 51 (see
By the lubricating-oil supply/exhaust means, lubricating oil is fed from the discharge port of an oil pump (now shown) via the main oil gallery (not shown) formed in the cylinder head into the annular space 44 and stays in the annular space 44. Thus, by the previously-discussed lubricating-oil supply/exhaust means, sufficient lubricating oil can be constantly fed to the needle bearing 38, large-diameter ball bearing 47, internal teeth 19a of annular member (inner peripheral meshing member) 19, rollers 48, and the roller retaining holes 41a of cage 41. By the way, small-diameter oil seal 46 functions to prevent a leakage of lubricating oil staying in the annular space 44 toward the housing 5 (in particular, toward the electric motor 12).
As shown in
The fundamental operation of the VTC apparatus of the embodiment is hereunder described in detail.
When the engine crankshaft rotates, timing sprocket 1 rotates in synchronism with rotation of the crankshaft through the timing chain 42. On the one hand, torque flows from the timing sprocket 1 through the annular member 19 via the female-screw-threaded annular portion 6 to the housing 5 of electric motor 12, and thus permanent magnets 14-15 and stator 16, all attached to the inner periphery of housing 5, rotate together with the housing 5. On the other hand, torque flows from the timing sprocket 1 through the annular member 19 via the rollers 48, cage 41, and driven member 9 to the camshaft 2. In this manner, the intake-valve cams of camshaft 2 are rotated for operating (opening/closing) the intake valves against the spring forces of valve springs.
During a predetermined engine operating condition after the engine start-up, an electric current is applied from control unit 40 through the terminal strips 31, 31, the pig-tale harnesses 33a-33b, the second brushes 30a-30b, and the slip rings 48a-48b to the electromagnetic coil 18 so as to perform normal-rotation/reverse-rotation control of motor output shaft 13. As a result, torque, produced by electric motor 12, is transmitted through the speed reducer (including the eccentric shaft portion 39, large-diameter ball bearing 47, rollers 48, cage 41, driven member 9, annular member 19, and needle bearing 38) to the camshaft 2, and thus an angular phase of camshaft 2 relative to timing sprocket 1 is controlled and changed.
That is, when eccentric shaft portion 39 rotates eccentrically during rotation of motor output shaft 13, each of rollers 48 moves and relocates from one of two adjacent internal teeth 19a, 19a to the other with one-tooth displacement per one complete revolution of motor output shaft 13, while being held in rolling-contact with the outer race 47b of large-diameter ball bearing 47 and simultaneously radially guided by the associated roller retaining holes 41a of cage 41. By way of the repeated relocations of each of rollers 48 every revolutions of motor output shaft 13, rollers 48 move in the circumferential direction with respect to the waveform internal toothed portion 19a of annular member 19, while being held in rolling-contact with the outer race 47b of large-diameter ball bearing 47. In this manner, torque is transmitted through driven member 9 to camshaft 2, while the rotational speed of motor output shaft 13 is reduced. The reduction ratio of this type of speed reducer 8 can be determined by the number of rollers 48 (in other words, the number of roller retaining holes 41a of cage 41). The fewer the number of rollers 48 (roller retaining holes 41a), the lower the reduction ratio.
As discussed above, by controlling of the operation of phase converter 4 (constructed by electric motor 12 and speed reducer 8), that is, by execution of the normal-rotation/reverse-rotation control of motor output shaft 13, an angular phase of camshaft 2 relative to timing sprocket 1 can be changed, and as a result intake-valve open timing (IVO) and intake-valve closure timing (IVC) can be phase-advanced or phase-retarded. As clearly shown in
That is to say, when driven member 9 (camshaft 2) rotates in the same rotation direction as timing sprocket 1 during eccentric rotary motion of eccentric shaft portion 39, the maximum normal-rotational motion of driven member 9 (camshaft 2) is restricted by abutment between the anticlockwise end face of radially-inward-protruding stopper portion if and the clockwise-opposing end face 2c of stopper recessed groove 2b. Thus, the angular phase of camshaft 2 relative to timing sprocket 1 is changed to the maximum phase-advance state.
Conversely, when driven member 9 (camshaft 2) rotates in the reverse-rotational direction during eccentric rotary motion of eccentric shaft portion 39, the maximum reverse-rotational motion of driven member 9 (camshaft 2) is restricted by abutment between the clockwise end face of radially-inward-protruding stopper portion if and the anticlockwise-opposing end face 2d of stopper recessed groove 2b. Thus, the angular phase of camshaft 2 relative to timing sprocket 1 is changed to the maximum phase-retard state.
As a result, intake-valve open timing and intake-valve closure timing can be properly phase-changed, so as to improve the engine performance, such as fuel economy and engine power output, depending on the engine/vehicle operating condition.
According to the phase-control system of the shown embodiment, the engine stops under a state where the phase angle of camshaft 2 relative to timing sprocket 1 (the crankshaft) has been changed to a phase angle differing from the computed required phase angle suited for the next engine starting during an engine stopping period (that is, a phase angle deviated toward the phase-advance side or the phase-retard side with respect to the required phase angle) in advance of an operating mode shift to an engine stopped state. Immediately after the next engine starting (e.g., immediately after cranking starts), a state transition of the phase-change mechanism (phase converter 4 involving electric motor 12) from a static-friction state to a dynamic-friction state is created by a preliminary phase change of the phase angle of camshaft 2 relative to the crankshaft in the phase-retard direction by alternating torque (load torque) inputted to camshaft 2 and by de-energizing electric motor 12 for instance during cold-engine starting, or by a preliminary, gradual phase change of the phase angle of camshaft 2 relative to the crankshaft in the phase-advance direction by energizing and driving electric motor 12 against the load torque input of camshaft 2 for instance during warm-engine starting.
[Phase-Change Control Executed when Starting Engine from Cold (Low Temperatures)]
First, phase-change control, executed by control unit 40 when starting/restarting the engine by turning the ignition switch (IGS) ON under a specified low-engine-temperature condition (a cold-engine state) where the engine temperature Tw is less than or equal to a predetermined temperature value T1, for instance when starting with a cold engine, is hereunder described in detail in reference to the time chart of
As can be seen from the time chart of
When restarting the engine from cold by turning the ignition switch ON after a long elapsed time from the engine-stop point, on the one hand, control unit 40 sets the required phase angle (indicated by the line “Q” in
Thereafter, immediately when cranking has started, by virtue of alternating torque, created owing to the valve-spring forces exerted on camshaft 2, the phase angle of camshaft 2 relative to the crankshaft can be automatically changed from the phase-advance side to the phase-retard side (see the control characteristic of the actual phase angle “P” within the area “B” in
At this point of time, phase-angle detection, executed within control unit 40, restarts based on a detected pulse signal from the phase-angle detection means, and simultaneously feedback (F/B) control for the phase angle of camshaft 2 relative to the crankshaft restarts, in the form of rotation control of electric motor 12, based on the detected phase angle.
In this manner, a state transition from a static-friction state to a dynamic-friction state occurs by positive phase-change from the phase-advance side to the phase-retard side in advance of the start of F/B control for phase angle of camshaft 2 relative to the crankshaft. Hence, it is possible to remarkably enhance the responsiveness of phase-change control for phase angle of camshaft 2 relative to the crankshaft, by means of phase converter 4.
Details of the concrete phase-change control routine, executed within control unit 40 when starting the engine from cold, are hereunder described in reference to the flowchart of
At step S1, a check is made to determine whether an ignition switch IGS is turned OFF by the driver. When the answer to step S1 is in the affirmative (YES), the routine proceeds to step S2. Conversely when the answer to step S1 is in the negative (NO), it is determined that the ignition switch IGS has already been turned ON and thus the engine is running. Hence, in the case that the answer to step S1 is negative, the routine proceeds to step S21 of the flowchart shown in
At step S2, a target phase angle “Q1” is set to a phase angle deviated toward the phase-advance side by a given angle with respect to a required phase angle “Q” suited for cold-engine-starting (the next engine starting). Subsequently to step S2, step S3 occurs. By the way, in the shown embodiment, to enable appropriate setting of target phase angle “Q1” toward the phase-advance side with respect to the required phase angle “Q”, the required phase angle “Q” is set to a phase angle between the maximum phase-advance position and the maximum phase-retard position.
At step S3, responsively to the target phase angle “Q1” set to the phase-advance side, a control current (a control signal) is outputted to electric motor 12 during a time period from the point of time at which the engine speed (the engine-crankshaft revolution speed) begins to decrease with the ignition switch IGS turned OFF to the point of time immediately before rotation of the crankshaft stops and thus the engine operating mode becomes completely shifted to a stopped state, so as to feedback-control, based on the target phase angle “Q1”, the phase angle of camshaft 2 relative to the crankshaft (in other words, the phase angle of phase converter 4) toward the phase-advance side.
At step S4, rotation of the crankshaft stops and thus the engine operating mode becomes completely shifted to a stopped state.
At step S5, a check is made to determine whether the ignition switch IGS becomes turned ON by the driver for starting or restarting the engine. When the answer to step S5 is in the negative (NO), the routine returns from step S5 to step S4. Conversely when the answer to step S5 is in the affirmative (YES), the routine proceeds to step S6.
At step S6, a check is made to determine whether the engine temperature (e.g., the engine coolant temperature Tw), detected during the engine starting/restarting period, is less than or equal to a predetermined low temperature value T1. When the answer to step S6 is in the affirmative (Tw≦T1), the routine proceeds to step S7. Conversely when the answer to step S6 is in the negative (Tw>T1), the routine proceeds to step S12.
At step S7, a check is made to determine whether the latest up-to-date information about the actual phase angle of camshaft 2 relative to the crankshaft has already reached the target phase angle “Q1” by F/B control via electric motor 12 of phase converter 4, during the previously-noted time period from the ignition-switch turned-OFF point to the point of time immediately before the engine-stop point. When the answer to step S7 is in the affirmative (YES), the routine proceeds to step S8. Conversely when the answer to step S7 is in the negative (NO), the routine proceeds to step S14.
At step S8, a control signal output to electric motor 12 is inhibited to inhibit an operating force from being applied via phase converter 4 to camshaft 2 until such time that phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, has initiated during the next engine starting period, thereby enabling the phase angle of camshaft 2 relative to the crankshaft to be automatically changed to the phase-retard side (in the phase-retard direction) by alternating torque, inputted to camshaft 2 owing to the valve-spring forces. Almost at this point of time of inhibition of operating force application to camshaft 2, cranking initiates. Subsequently to step S8, step S9 occurs.
At step S9, the phase-control mode is shifted to a normal F/B control mode (normally executed based on the required phase angle “Q” and the detected phase angle “R”), immediately after phase-angle detection executed within control unit 40 has restarted, for converging the phase angle of camshaft 2 into the required phase angle “Q”, suited for cold-engine-starting (i.e., Tw≦T1). Thereafter, step S10 occurs.
At step S10, the engine starts.
At step S11, at the normal F/B control mode, the phase angle of camshaft 2 relative to the crankshaft (in other words, the phase angle of phase converter 4) is controlled to a normal required phase angle (suited for a normal engine operating condition).
Under a specific engine temperature condition defined by Tw>T1, the routine shifts from step S6 to step S12.
At step S12, a control signal output (a control current output) to electric motor 12 (in other words, energization of electric motor 12) is inhibited to inhibit an operating force from being applied via phase converter 4 to camshaft 2 until such time that phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, has restarted during the next engine starting period, thereby enabling the phase angle of camshaft 2 relative to the crankshaft to be automatically changed to the phase-retard side (in the phase-retard direction) by alternating torque, exerted on camshaft 2 due to initiation of cranking. Thereafter, step S13 occurs.
At step S13, the phase-control mode is shifted to a normal F/B control mode (normally executed based on the required phase angle “Q” and the detected phase angle “R”), immediately after phase-angle detection executed within control unit 40 has restarted, for converging the phase angle of camshaft 2 into the required phase angle “Q”, suited for engine-starting in the detected engine temperature Tw. Thereafter, the routine shifts from step S13 to step S10.
Under a specific condition where the target phase angle “Q1” has not yet been reached during the previously-noted time period from the ignition-switch turned-OFF point to the point of time immediately before the engine-stop point, the routine shifts from step S7 to step S14.
At step S14, a check is made to determine whether the phase angle of camshaft 2 (in other words, the phase angle of phase converter 4), detected immediately before the engine-stop point, exists on the phase-advance side with respect to the required phase angle “Q”, suited for cold-engine-starting. When the answer to step S14 is in the affirmative (YES), the routine advances to step S8. Conversely when the answer to step S14 is in the negative (NO), the routine advances to step S15.
At step S15, responsively to a control signal output to electric motor 12, a given operating force is applied via phase converter 4 to camshaft 2 until such time that phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, has restarted during the next engine starting period, thereby enabling the phase angle of camshaft 2 relative to the crankshaft to be changed to the phase-advance side (in the phase-advance direction) by the given operating force applied to camshaft 2. Thereafter, the routine shifts from step S15 to step S9.
In this manner, in a situation where the engine is started from cold (low temperatures), the phase angle (the actual phase angle “P”) of camshaft 2 relative to the crankshaft is changed to the target phase angle “Q1” existing on the phase-advance side opposite to the required phase angle “Q” existing on the phase-retard side and suited for cold-engine-starting, in advance, by rotation control of electric motor 12 during the engine stopping period. After this, during the time period from (i) the time when cranking starts during the next engine starting period to (ii) the time when F/B control for the phase angle of camshaft 2 starts immediately after phase-angle detection executed within control unit 40 has restarted, a phase-change of the actual phase angle “P” of camshaft 2 (in other words, a phase-change of the phase angle of phase converter 4) from the target phase angle “Q1” of the phase-advance side to the required phase angle “Q” of the phase-retard side occurs in advance of the start of F/B control. By this, a state transition from a static-friction state to a dynamic-friction state occurs by the positive phase-change from the phase-advance side to the phase-retard side in advance of the start of F/B control.
Hence, it is possible to remarkably enhance the responsiveness of phase-change control for phase angle of camshaft 2 relative to the crankshaft, achieved by phase converter 4, from the point of time immediately after F/B control has initiated or restarted. By virtue of such a state transition to a dynamic-friction state, it is also possible to enhance the phase-change control stability.
Additionally, such a phase change of camshaft 2 to the phase-retard side can be achieved by alternating torque, inputted to camshaft 2 owing to the valve-spring forces during cranking, without using an operating force, produced by electric motor 2. This contributes to reduced electric power consumption. In more detail, when starting the engine from cold, the relative phase angle of camshaft 2 (during the engine stopping period) is controlled to a phase angle deviated toward the phase-advance side with respect to the required phase angle “Q”. Hence, as soon as cranking initiates with the ignition switch turned ON, a self-return force toward the phase-retard side, caused by alternating torque (load torque) exerted on camshaft 2, acts on the phase converter 4. The self-return force serves as an assisting force that assists a phase-change action of phase converter 4 toward the required phase angle “Q”. Thereafter, the F/B control, subsequently to such self-return of phase converter 4 toward the phase-retard side (the required phase angle “Q”), starts. Hence, it is possible to enhance the responsiveness of phase-change action of phase converter 4 during the subsequent feedback control. Utilizing such a self-return force facilitates the phase-change control.
Furthermore, the phase-control system is configured so that the engine can start/restart, while directing or changing the phase angle (the actual phase angle “P”) of camshaft 2 relative to the crankshaft in the phase-retard direction from the target phase angle “Q1”, set to the phase-advance side with respect to the required phase angle “Q”, during the cold-engine starting period. This contributes to a good engine startability during the cold-engine starting period.
[Phase-Change Control Executed when Restarting Engine from Warmed-Up State (High Temperatures)]
Next, phase-change control, executed by control unit 40 when restarting the engine from a high-engine-temperature state (a warmed-up engine state) where the engine temperature Tw is greater than or equal to a predetermined temperature value T2, for instance, when automatically restarting the engine for a short time elapsed after the engine has been automatically stopped by a so-called idle-stop function (or an idling-stop function), is hereunder described in detail in reference to the time chart of
As can be seen from the time chart of
When automatically restarting the engine from the warmed-up state (the high-engine-temperature state) after a short elapsed time from the engine-stop point, control unit 40 sets the required phase angle (indicated by the line “Q” in
Thereafter, during a time period from the point of time at which cranking starts to the point of time at which phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, restarts, responsively to a control signal output to electric motor 12, a given operating force, corresponding to the control signal, is forcibly applied via phase converter 4 to camshaft 2, thereby changing the phase angle of camshaft 2 relative to the crankshaft from the phase-retard side (i.e., the target phase angle “Q2”) to the phase-advance side (i.e., the required phase angle “Q”) by the applied operating force (see the control characteristic of the actual phase angle “P” within the area “D” in
At this point of time, phase-angle detection, executed within control unit 40, restarts based on a detected pulse signal from the phase-angle detection means, and simultaneously feedback (F/B) control for the phase angle of camshaft 2 relative to the crankshaft restarts, in the form of rotation control of electric motor 12, based on the detected phase angle.
In this manner, a state transition from a static-friction state to a dynamic-friction state occurs by forcible phase-change from the phase-retard side to the phase-advance side in advance of the start of F/B control for phase angle of camshaft 2 relative to the crankshaft. Hence, it is possible to remarkably enhance the responsiveness of phase-change control for phase angle of camshaft 2 relative to the crankshaft, by means of phase converter 4.
Details of the concrete phase-change control routine, executed within control unit 40 when automatically restarting the engine from its warmed-up state, are hereunder described in reference to the flowchart of
At step S21, a check is made to determine whether an engine-stop instruction (an engine-stop command signal) has been outputted from the control unit 40. In other words, a check is made to determine whether an idle-stop function has been activated. When the answer to step S21 is in the negative (NO), it is determined that the engine is running and then the routine proceeds to step S31. Conversely when the answer to step S21 is in the affirmative (YES), according to the engine-stop instruction the routine proceeds to step S22.
At step S22, a target phase angle “Q2” is set to a phase angle deviated toward the phase-retard side by a given angle with respect to a required phase angle “Q” suited for warm-engine-starting (the next engine starting). Subsequently to step S22, step S33 occurs. By the way, in the shown embodiment, to enable appropriate setting of target phase angle “Q2” toward the phase-retard side with respect to the required phase angle “Q”, the required phase angle “Q” is set to a phase angle between the maximum phase-advance position and the maximum phase-retard position.
At step S23, responsively to the target phase angle “Q2” set to the phase-retard side, a control current (a control signal) is outputted to electric motor 12 during a time period from the point of time at which the engine speed (the engine-crankshaft revolution speed) begins to decrease by activation of the idle-stop function to the point of time immediately before rotation of the crankshaft stops and thus the engine operating mode becomes completely shifted to a stopped state, so as to feedback-control, based on the target phase angle “Q2”, the phase angle of camshaft 2 relative to the crankshaft (in other words, the phase angle of phase converter 4) toward the phase-retard side.
At step S24, rotation of the crankshaft stops and thus the engine operating mode becomes completely shifted to a stopped state.
At step S25, a check is made to determine whether the electric power source becomes turned ON by releasing the brake pedal for activation of an automatic engine-restart function. When the answer to step S25 is in the negative (NO), the routine returns from step S25 to step S24. Conversely when the answer to step S25 is in the affirmative (YES), the routine proceeds to step S26.
At step S26, a check is made to determine whether the engine temperature (e.g., the engine coolant temperature Tw), detected during the engine restarting period, is greater than or equal to a predetermined temperature value T2. When the answer to step S26 is in the affirmative (Tw≧T2), the routine proceeds to step S27. Conversely when the answer to step S26 is in the negative (Tw<T2), the routine proceeds to step S32.
At step S27, a check is made to determine whether the latest up-to-date information about the actual phase angle of camshaft 2 relative to the crankshaft has already reached the target phase angle “Q2” by F/B control via electric motor 12 of phase converter 4, during the previously-noted time period from the idle-stop-function activated point to the point of time immediately before the engine-stop point. When the answer to step S27 is in the affirmative (YES), the routine proceeds to step S28. Conversely when the answer to step S27 is in the negative (NO), the routine proceeds to step S34.
At step S28, responsively to a control signal output to electric motor 12, a given operating force is applied via phase converter 4 to camshaft 2 until such time that phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, has restarted during the next engine starting period, thereby enabling the phase angle of camshaft 2 relative to the crankshaft to be changed to the required phase angle “Q” suited for warm-engine-starting, that is, in the phase-advance direction, by the given operating force applied to camshaft 2. Subsequently to step S28, step S29 occurs.
At step S29, the phase-control mode is shifted to a normal F/B control mode (normally executed based on the required phase angle “Q” and the detected phase angle “R”), immediately after phase-angle detection executed within control unit 40 has restarted, for converging the phase angle of camshaft 2 into the required phase angle “Q”, suited for warm-engine-starting (i.e., Tw≧T2). Thereafter, step S30 occurs.
At step S30, the engine starts.
At step S31, at the normal F/B control mode, the phase angle of camshaft 2 relative to the crankshaft (in other words, the phase angle of phase converter 4) is controlled to a normal required phase angle (suited for a normal engine operating condition) via the phase converter 4.
Under a specific engine temperature condition defined by Tw<T2, the routine shifts from step S26 to step S32.
At step S32, a control signal output to electric motor 12 is inhibited to inhibit an operating force from being applied via phase converter 4 to camshaft 2 until such time that phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, has restarted during the next engine starting period, thereby enabling the phase angle of camshaft 2 relative to the crankshaft to be automatically changed to the phase-retard side (in the phase-retard direction) by alternating torque, exerted on camshaft 2 due to initiation of cranking. Thereafter, step S33 occurs.
At step S33, the phase-control mode is shifted to a normal F/B control mode (normally executed based on the required phase angle “Q” and the detected phase angle “R”), immediately after phase-angle detection executed within control unit 40 has restarted, for converging the phase angle of camshaft 2 into the required phase angle “Q”, suited for engine-starting in the detected engine temperature Tw. Thereafter, the routine shifts from step S33 to step S30.
Under a specific condition where the target phase angle “Q2” has not yet been reached during the previously-noted time period from the idle-stop-function activated point to the point of time immediately before the engine-stop point, the routine shifts from step S27 to step S34.
At step S34, a check is made to determine whether the phase angle of camshaft 2 (in other words, the phase angle of phase converter 4), detected immediately before the engine-stop point, exists on the phase-retard side with respect to the required phase angle “Q”, suited for warm-engine-starting. When the answer to step S34 is in the affirmative (YES), the routine advances to step S28. Conversely when the answer to step S34 is in the negative (NO), the routine advances to step S35.
At step S35, a control signal output to electric motor 12 is inhibited to inhibit an operating force from being applied via phase converter 4 to camshaft 2 until such time that phase-angle detection of camshaft 2 relative to the crankshaft, executed within control unit 40, has restarted during the next engine starting period, thereby enabling the phase angle of camshaft 2 relative to the crankshaft to be automatically changed to the phase-retard side (in the phase-retard direction) by alternating torque, exerted on camshaft 2 due to initiation of cranking. Thereafter, the routine shifts from step S35 to step S29.
In this manner, when the engine is restarted from warm or hot (high temperatures), for instance in automotive vehicles having an idle-stop function, the phase angle (the actual phase angle “P”) of camshaft 2 relative to the crankshaft is changed to the target phase angle “Q2” existing on the phase-retard side opposite to the required phase angle “Q” existing on the phase-advance side and suited for warm-engine-starting, in advance, by rotation control of electric motor 12 during the engine stopping period. After this, during the time period from (i) the time when cranking starts during the next engine starting period to (ii) the time when F/B control for the phase angle of camshaft 2 starts immediately after phase-angle detection executed within control unit 40 has restarted, a phase-change of the actual phase angle “P” of camshaft 2 (in other words, a phase-change of the phase angle of phase converter 4) from the target phase angle “Q2” of the phase-retard side to the required phase angle “Q” of the phase-advance side occurs in advance of the start of F/B control. By this, a state transition from a static-friction state to a dynamic-friction state occurs by the positive phase-change from the phase-retard side to the phase-advance side in advance of the start of F/B control.
Hence, it is possible to remarkably enhance the responsiveness of phase-change control for phase angle of camshaft 2 relative to the crankshaft, achieved by phase converter 4, from the point of time immediately after F/B control has initiated or restarted. By virtue of such a state transition to a dynamic-friction state, it is also possible to enhance the phase-change control stability. Furthermore, the phase-control system is configured so that the engine can restart, while directing or changing the phase angle (the actual phase angle “P”) of camshaft 2 relative to the crankshaft in the phase-advance direction from the target phase angle “Q2”, set to the phase-retard side with respect to the required phase angle “Q”, during the warm-engine starting period. This contributes to a good engine startability during the warm-engine starting period.
Also, to ensure a better warm-engine startability, in the shown embodiment, regarding an engine startable phase-angle range, within which the engine can start under a state where engine temperature (e.g., engine coolant temperature Tw) is greater than or equal to the predetermined temperature value T2, a phase-retard side startable phase-angle range with respect to the required phase angle “Q” is set to be wider than a phase-advance side startable phase-angle range with respect to the required phase angle “Q”.
Additionally, in the shown embodiment, an amount of electric current, which current is supplied to electric motor 12 driven in the direction that the phase angle of camshaft 2 is brought closer to the required phase angle “Q” during the time period from the point of time when cranking starts to the point of time when detection of the rotational position of camshaft 2, executed within the phase angle detector of the controller, initiates, is controlled to increase, as engine temperature (e.g., engine coolant temperature Tw) decreases. This ensures the enhanced responsiveness of phase-change action of phase converter 4 during the engine starting period, regardless of a change in engine temperature.
Moreover, in the shown embodiment, the phase angle of camshaft 2 to be held during the stopping period of the engine is altered depending on the detected engine temperature (engine coolant temperature Tw).
The above-mentioned phase-change control, executed when restarting the engine from its warmed-up state, is exemplified in automotive vehicles having an idle-stop function and an automatic engine-restart function. It will be appreciated that this phase-change control is not limited to the application to such an idling-stop-system equipped vehicle. The phase-change control mode for engine-restarting from the warmed-up state may be applied to any situation where an engine is restarted after a short elapsed time from an ignition-switch turned-off point even in a non-idling-stop-system equipped vehicle.
Control unit 40 is also configured to execute phase-control from the phase-advance side or the phase-retard side to the required phase angle “Q” via phase converter (4) (via electric motor 12) without any overshoot, in advance of an operating mode shift to an engine stopped state. In contrast, suppose that undesirable hunting (overshoot and undershoot) takes place during phase-control to the required phase angle “Q”. This leads to a long settling time, that is, lowered phase-change control responsiveness. To avoid this, in the shown embodiment, control unit 40 is configured to phase-change the actual phase angle “P” of camshaft 2 relative to the crankshaft to the required phase angle “Q” without any overshoot, in advance of the start of normal F/B control, normally executed based on the required phase angle “Q” and the detected phase angle “R”. That is, the feedback-control (F/B) system is configured such that phase converter 4 is operated by feedback-control without any overshoot that the system output response proceeds beyond the required phase angle “Q”.
Moreover, in the shown embodiment, regarding the phase difference (|Q1−Q1|; |Q2−Q|) between (i) the target phase angle “Q1” (set immediately after an engine-stop point in a cold-engine state) or “Q2” (set immediately after an engine-stop point in a warm-engine state) and (ii) the required phase angle “Q”, the lower the engine temperature, the less phase difference is set. That is, the phase difference (|Q1−Q|; |Q2−Q|) can be reduced in accordance with a decrease in engine temperature, thus ensuring shortened arrival time to the required phase angle “Q” during the engine staring period.
Furthermore, in the shown embodiment, the phase-change control system (control unit 40) is configured to perform normal-rotation/reveres-rotation control of motor output shaft 13 such that electric motor 12 of phase converter 4 is driven (rotated) in the same direction of rotation immediately before and immediately after initiation (start) of normal F/B control, by which the phase angle of camshaft 2 can be brought closer to the required phase angle “Q” by feeding back the result of detection of the phase angle detector (i.e., the detected phase angle “R”). In other words, the phase-change control system (control unit 40) is configured to start normal F/B control, by which the phase angle of camshaft 2 can be brought closer to the required phase angle “Q” by feeding back the result of detection of the phase angle detector, in a manner so as to drive the electric motor in the same rotational direction continuously from a state where electric motor 12 has already rotated in advance during the engine starting period. Thus, it is possible to effectively suppress an undesirable time loss occurring when electric motor 12 is rotated reversely, and/or an undesirable overshoot of phase-change control occurring when a revolution speed of electric motor 12 becomes excessive.
Additionally, in the shown embodiment, as shown in
Also, by fastening the bracket portions 28c, 28c with bolts 36, 36, seal member 34 is elastically deformed and brought into elastic-contact with the annular front end face of cylindrical wall portion 3b, thereby providing a good seal between the outer peripheral surface of brush retaining portion 28a and the annular front end face of cylindrical wall portion 3b.
As discussed above, by axial installation of the brush retaining portion 28a of brush retainer 28 with the second brushes 30a-30b and coil springs 32a-32b into the brush-retainer bore 3c of cover member 3, the second brushes 30a-30b can be brought into abutted-engagement (elastic-contact) with the respective slip rings 26a-26b in place, without providing any stopper for positioning. This contributes to easy assembling work, lower system installation time and costs, and reduced service time.
Additionally, at the initial stage of axial installation (insertion) of the brush retaining portion 28a with the second brushes 30a-30b and coil springs 32a-32b into the brush-retainer bore 3c, the second brushes 30a-30b become still kept out of contact with the respective slip rings 26a-26b, but at the last stage of the axial installation the second brushes 30a-30b can be reliably brought into elastic-contact (sliding electrical contact) with the respective slip rings 26a-26b owing to the previously-described dimensional relationship between the length L and the length L1, that is, L<L1. This ensures the stable operating ability (the stable, good electric-current supply) of the brush-retaining structure.
The entire contents of Japanese Patent Application No. 2011-003793 (filed Jan. 12, 2011) are incorporated herein by reference.
While the foregoing is a description of the preferred embodiments carried out the invention, it will be understood that the invention is not limited to the particular embodiments shown and described herein, but that various changes and modifications may be made without departing from the scope or spirit of this invention as defined by the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-003793 | Jan 2011 | JP | national |
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