The present application relates to a fuel pump drive system coupled with variable cam timing actuators.
Engines with direct fuel injection may use high pressure fuel pumps to provide sufficient fuel pressure to the injectors. In some examples, the high pressure fuel pump may be driven by a cam lobe on the engine camshaft. In some cases, such a fuel pump drive lobe may be integrated into the camshaft where the valve timing is being actively phased during engine operation.
The inventors of the present application have recognized a problem in such previous approaches in that the fuel pump is typically driven “downstream” (in terms of power flow) of hydraulic actuators used to actively adjust timing of the intake and exhaust cams. For example, in previous approaches, the fuel pump may be driven at a camshaft side of a variable cam timing (VCT) actuator, whereas the VCT actuator is driven at the crankshaft side of the actuator by the crankshaft, e.g., via a timing chain. In such situations, when adjusting the phasing of the VCT actuator, the actuator may have to work against significant resistance by the fuel pump. Therefore, actuating a high pressure fuel pump in such a manner may adversely affect transient control of the valve timing, for example, by significantly decreasing the shifting velocity of the VCT actuator. If the shift velocity becomes too low, the performance, emissions and fuel economy of the engine may be degraded.
In one example, some of the above issues may be addressed by a system for an engine driven by an engine crankshaft. Such a system may include a first variable cam device including a first hydraulic actuator, and a second variable cam device including a second hydraulic actuator. The system may further include an intermediate power transfer mechanism, such as a gear or drive shaft, coupled between the first variable cam device and the second variable cam device upstream, in a direction of power flow from the engine crankshaft, of the first hydraulic actuator and the second hydraulic actuator. The system may further include an auxiliary device, such as a fuel pump, coupled to and driven by the intermediate power transfer mechanism.
In this way, the resistance torque of the fuel pump actuation may be located upstream of the first and second hydraulic actuators (e.g., at a sprocket side of the VCT actuators). As such, adjustment of the variable camshafts, for example variable cam timing, may be more accurately provided since adjustments to the camshaft are not required to overcome the fuel pump resistance torque.
Further, the fuel pump drive system may serve as a secondary timing drive coupling the housings of the first and second VCT devices, as well as the drive for the fuel pump. In the example of the drive shaft, it may rotationally couple a first and second camshaft in an overhead camshaft configuration, and thus a timing chain or belt between the two camshafts can be eliminated. Moreover, the claimed configuration can be packaged to fit between the intake and exhaust camshafts, where given the physical constraints of the configuration, a chain may not be suitable.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
Embodiments of a fuel pump drive system actuated upstream (in terms of power flow) of hydraulic actuators of a variable cam timing system, and methods of operating such a fuel pump drive system, are disclosed herein. Such a fuel pump system may be utilized with an engine, as described hereafter.
Combustion chamber 130 may receive intake air from intake manifold 146 via an intake passage and may exhaust combustion gases via exhaust passage 148. Intake manifold 146 and exhaust passage 148 can selectively communicate with combustion chamber 130 via respective intake valve 152 and exhaust valve 154. In some embodiments, combustion chamber 130 may include one or more intake valves and one or more exhaust valves.
In this example, intake valve 152 and exhaust valve 154 may be controlled by cam actuation via respective cam actuation systems 151 and 153. As shown in this example, cam actuation systems 151 and 153 correspond to camshafts that actuate a plurality of valves in a plurality of cylinders. Further, the cams may actuate valves of cylinders in a common bank. Cam actuation systems 151 and 153 may each include one or more cams and may utilize one or more of cam profile switching (CPS), variable cam timing (VCT), variable valve timing (VVT) and/or variable valve lift (VVL) systems that may be operated by the controller to vary valve operation. The position of intake valve 152 and exhaust valve 154 may be determined by position sensors 155 and 157, respectively.
Fuel injector 166 is shown coupled directly to combustion chamber 130 for injecting fuel directly therein in proportion to the pulse width of signal FPW received from the controller via an electronic driver. In this manner, fuel injector 166 provides what is known as direct injection of fuel into combustion chamber 130. The fuel injector may be mounted in the side of the combustion chamber or in the top of the combustion chamber, for example. Fuel may be delivered to fuel injector 166 by a fuel system including a fuel tank (not shown), a fuel pump 168, and a fuel rail (not shown). In some embodiments, combustion chamber 130 may alternatively or additionally include a fuel injector arranged in intake manifold 146 in a configuration that provides what is known as port injection of fuel into the intake port upstream of combustion chamber 130.
An ignition system can provide an ignition spark to combustion chamber 130 via spark plug 192 in response to spark advance signal from the controller, under select operating modes. Though spark ignition components are shown, in some embodiments, combustion chamber 130 or one or more other combustion chambers of engine 100 may be operated in a compression ignition mode, with or without an ignition spark.
Engine 100 further includes a fuel pump drive system 167 actuated by cam actuation systems 151 and 153. As an example, in the case of variable cam timing, each of the cam actuation systems 151 and 153 may include an input component (e.g., a housing) which receives and transfers power via a hydraulic fluid to an output component (e.g., a hydraulic actuator). Accordingly, the housing is rotatable with respect to the hydraulic actuator. Fuel pump drive system 167 is actuated upstream (in a direction of power flow from the engine crankshaft) of the output components of each of the cam actuation systems 151 and 153. Thus, the shifting velocity of the output components is not affected by actuation of the fuel pump drive system. Embodiments of a fuel pump drive system are described in more detail as follows.
First camshaft 204 and second camshaft 212 may be of any suitable configuration. One suitable configuration includes first camshaft 204 being sufficiently parallel to second camshaft 212. Further, first camshaft 204 and second camshaft 212 may be of a same bank. In some embodiments, first camshaft 204 may be an exhaust camshaft and second camshaft 212 may be an intake camshaft. Alternatively, in other embodiments, first camshaft 204 may be an intake camshaft and second camshaft 212 may be an exhaust camshaft.
Fuel pump drive system 200 may further include an intermediate power transfer mechanism, such as drive shaft 218 coupled between first variable cam device 202 and second variable cam device 210, upstream of the first hydraulic actuator 206 and the second hydraulic actuator 214. Such coupling can be done in any suitable manner, for example, via bevel gears, and is described in more detail with reference to
For example,
In such an embodiment, by coupling drive shaft 218 between first housing 208 and second housing 216, the drive shaft is upstream of first hydraulic actuator 206 and second hydraulic actuator 214. In other words, a first end of drive shaft 218 may be coupled to first housing 208 upstream of first hydraulic actuator 206, and a second end of drive shaft 218 may be coupled to second housing 216 upstream of the second hydraulic actuator 214.
Further, drive shaft 218 may be positioned perpendicular to first camshaft 204 and second camshaft 212. For example, drive shaft 218 may be positioned between first housing 208 and second housing 216 at a right angle with respect to the first camshaft and the second camshaft.
Continuing with
While
As described above, crank 222 may be coupled to first housing 208. It can be appreciated that such a crank may be coupled to one of the first housing and the second housing. Accordingly,
Similarly, a second camshaft 410 may be driven by a second hydraulic actuator 412, wherein second hydraulic actuator 412 is actuated by hydraulic fluid of a second variable cam timing device, such that second hydraulic actuator 412 is rotatable with respect to a second housing 414. The second housing 414 is coupled to the first housing via a drive shaft 416. In other words, power may be transferred from first housing 404 to second housing 414 via drive shaft 416, as described in more detail below. First camshaft 408 and second camshaft 410 may be of a same cylinder bank. For example, in one embodiment first camshaft 408 may be an exhaust camshaft and second camshaft 410 may be an intake camshaft. In an alternate embodiment, first camshaft 408 may be an intake camshaft and second camshaft 410 may be an exhaust camshaft.
Drive shaft 416 may be coupled to first housing 404 in any suitable manner. One such suitable coupling is a bevel gear 418, such that rotation of first housing 404 may be transferred via the bevel gear to induce rotation of drive shaft 416. In some embodiments, drive shaft 416 may be positioned at a right angle with respect to first camshaft 408 and second camshaft 410. In such embodiments, the two axes of bevel gear 418 may be at right angles with respect to one another as well. Likewise, a bevel gear 420 may be used to couple drive shaft 416 to second housing 414. As such, drive shaft 416 may serve as a second timing drive for coupling first housing 404 to second housing 414.
Drive shaft 416 may further include a fuel pump drive lobe 422 for driving a fuel pump 424. In some embodiments, fuel pump 424 may be a high pressure fuel pump. Thus, drive shaft 416 serves as a combined drive, in that it may replace a traditional configuration of a fuel pump drive on a cam, a secondary chain, a secondary tensioner, and secondary chain wear faces. Further, by driving the fuel pump upstream of where the valve timing is being phased, the shifting velocity is not affected, and therefore performance, emissions and fuel economy are not degraded.
Drive shaft 416 may further include thrust bearings and/or journal bearings to support drive shaft 416. Such bearings may be positioned in any suitable locations. In the depicted embodiment, a first thrust bearing 426 may be positioned on the drive shaft 416 between the first end of the drive shaft which is coupled to the first housing and the fuel pump drive lobe 422. Likewise, a second thrust bearing 428 may be positioned on the drive shaft 416 between the second end of the drive shaft which is coupled to the second housing and the fuel pump drive lobe 422. First thrust bearing 426 and second thrust bearing 428 may provide axial support to the drive shaft by constraining axial movement of the drive shaft.
As further shown, drive shaft 416 may include a first journal bearing 430 positioned on the drive shaft 416 between the first thrust bearing 426 and the fuel pump drive lobe 422. Likewise, a second journal bearing 432 positioned on the drive shaft 416 between the second thrust bearing 428 and the fuel pump drive lobe 422. First journal bearing 430 and second journal bearing 432 may provide rotor support to the drive shaft 416 by constraining radial movement of the drive shaft 416.
As such, rotating the drive shaft may include actuating first thrust bearing 426 and second thrust bearing 428. Accordingly, such rotation may further include actuating first journal bearing 430 and second journal bearing 432. In some embodiments, pump drive system 400 may further include a drive housing 434 surrounding a portion of drive shaft 416 and bolted to a cylinder head of the engine. Drive housing 434 may be of any suitable type. In the depicted embodiment, drive housing 434 partially surrounds fuel pump drive lobe 422, the first journal bearing 430 and the second journal bearing 432. In such an embodiment, drive housing 434 may be positioned on the drive shaft 416 between the first thrust bearing 426 and the second thrust bearing 428.
Although the above configuration is described in the context of an example where the first variable cam timing device 702 is being driven by the crank, it can be appreciated that the second variable cam timing device 704 may instead be driven by the crank.
Rotation of pump shaft gear 710 actuates a pump shaft 716 which then actuates a pump. As an example, pump shaft 716 may be coupled to a pump drive cam 718, such that rotation of pump shaft 716 causes pump drive cam 718 to actuate the pump. Further, in some embodiments, bearing journals such as bearing journals 720 may be used to provide rotor support to pump shaft 716 by constraining radial movement of pump shaft 716. Housings such as pump shaft housing 722 may be used to variously enclose portions of pump shaft 716, pump drive cam 718 and/or bearing journals 720. It will be appreciated that the configurations disclosed herein are exemplary in nature, and that these specific embodiments are not to be considered in a limiting sense, because numerous variations are possible. For example, the above technology can be applied to V-6, I-4, I-6, V-12, opposed 4, and other engine types. The subject matter of the present disclosure includes all novel and nonobvious combinations and subcombinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application.
Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
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