1. Field of the Invention
The present invention is generally directed toward manufacturing methods and, more particularly, toward a method and device for reliably setting a tappet clearance.
2. Description of the Related Art
Tappet clearance is the distance between a bottom surface of an adjustment or tappet screw and an upper surface of a valve. Accurately setting the tappet clearance, which is vital to proper operation of the engine, is time-consuming and labor-intensive.
Various methods and devices for manually adjusting tappet screws are known in the art. In accordance with one conventional method, the crankshaft or cam is put in the proper angular orientation, and feeler gauges are inserted between the tappet screw and the valve stem. The tappet screw then is rotated until the screw engages the valve stem. Then a wrench is used to tighten the jam nut to hold the tappet screw in position. This manual method requires positioning the feeler gauge, adjusting the tappet screw and then tightening the nut without disturbing the position of the tappet screw. It is often difficult to accomplish all of the actions precisely and repeatably, and it is usually awkward to have all of the required tools in position simultaneously.
Further, various devices have been developed to facilitate setting tappet clearance. For example, the tool in U.S. Pat. No. 6,345,436 provides a member for rotating the screw toward or away from the valve, and means for limiting the force applied to the screw. U.S. Pat. No. 6,450,072 discloses a tool in which the tappet screw is adjusted by a hand-operated device that does not apply more than a predetermined torque limit, with a torque wrench which is used to loosen and tighten the jam nut. The proper amount of torque is achieved by the use of a clutch mechanism. This tool requires the operator to have the proper feel for the appropriate amount of torque. The operator may override the torque setting by exceeding the designated number of clicks produced by the clutch mechanism, by turning the tool too fast, or by applying excessive force to the handle. If the proper torque is not applied to the screw, the clearance will be set incorrectly. In addition, the tool requires a repetitive motion that has ergonomic deficiencies.
While these devices may operate generally satisfactorily, improvements to the process of setting tappet clearance is desired. Particularly, the known devices and methods rely upon user expertise to in order to properly set tappet clearance. As a result, the possibility of error with conventional devices is unreasonably high. Therefore, a need exists for an improved tool and method for setting tappet clearance that is less dependent on operator expertise.
The present invention provides a method and tool for setting tappet clearance. In accordance with the present invention, the tappet screw can be set to the desired clearance using a tool that is easy to handle and operate.
The tool of the present invention includes a power-driven screwdriver portion, a pneumatic portion, and a controller. The pneumatic portion introduces a controlled flow of air into the engine, and the controller monitors the air flow and controls operation of the screwdriver to rotate a tappet screw and thereby set the tappet clearance.
The method includes engaging the screwdriver to a tappet screw and inserting the pneumatic portion into a spark plug hole. The pneumatic portion introduces an air flow into the cylinder via the spark plug hole, the air flow being monitored by the pneumatic portion and a controller. The controller instructs the screwdriver to selectively tighten and loosen the tappet screw based on the monitored air flow through the cylinder so as to position the tappet screw in a reference position. Starting from the reference position, the controller instructs the screwdriver to rotate the tappet screw a predetermined number of degrees to set the desired tappet clearance.
In accordance with the present invention, upon initiation of the process, the controller monitors the air flow and detects a stabilization of the air flow. Once the air flow stabilizes, the controller instructs the screwdriver to tighten the tappet screw. Once the air flow increases, which is indicative of the valve opening, the controller instructs the screwdriver to reverse direction so as to loosen the tappet screw. Then, when the controller detects a stabilization of the air flow, indicative of the valve being closed, the controller stops the screwdriver, and instructs the screwdriver to rotate the tappet screw in a loosening direction a predetermined number of degrees to thereby set the tappet clearance.
In further accordance with the present invention, the air flow is monitored by a mass air flow meter that converts the detected air flow into a voltage proportional to the amount of air flow. The voltage is provided to the controller, and the controller directs a plurality of outputs to operate the screwdriver in response to the voltage.
These and further features of the invention will be apparent with reference to the following description and drawings, wherein:
The invention will now be described in accordance with its preferred embodiments. The description with reference to the figures is intended to simplify the explanation of the invention and is not meant to limit the scope of the invention.
With reference to
The cylinder head 20 also carries components that serve to controllably open and close the valves 22 in an ordered fashion. The components include a multi-lobe cam shaft 38 and a series of rocker arms 40, each rocker arm 40 being associated with one of the valves 22.
With continued reference to
The tappet screw 50 has a tappet nut 52 thereon. After the tappet screw 50 is in a desired position or spacing relative to the valve stem 26, the tappet nut 52 is tightened to prevent unintended rotation of the tappet screw 50 relative to the rocker arm 40. Preferably, the tappet screw 50 has a very fine thread pitch to permit precise adjustment of the position of a lower end 54 of the tappet screw 50 and, hence, tappet clearance. Rotation of the tappet screw 50 varies the spacing between the lower or engagement end 54 of the tappet screw 50 and an upper or engaged surface 27 of the valve stem 26. Setting of the tappet clearance is one of the final steps in engine assembly, and is performed with the cylinder head 20 installed on the cylinder block.
With reference to
The tappet setting device 102 generally operates by moving the tappet screw 50 into a tappet reference point or position, and then rotating the tappet screw 50 a set number of degrees from the reference point or position so as to achieve the correct tappet clearance. The reference position, in the present embodiment, is defined as the tappet screw position at which the valve 22 is closed and the tappet screw 50 is in engagement with the valve stem 26 such that any tightening rotation of the tappet screw 50 will cause the valve 22 to open. According to the present invention, to reliably place the tappet screw 50 in the reference position, the tappet screw 50 is tightened to open the valve 22, and then loosened to close the valve 22. Whether the valve 22 is open or closed is determined pneumatically, as will be apparent from the following discussion.
The tappet setting device 102, as shown in
With reference to
The mass air flow meter 116 is connected to the pneumatic plug 114, which is, itself, inserted into the spark plug opening 58 by the operator. The mass air flow meter 116 generates a voltage proportional to the air flow sensed flowing therethrough, and outputs the voltage to the controller 108, as will be described in further detail hereinafter.
As shown in
The controller 108, schematically illustrated in
With reference to
As mentioned above, the tappet clearance setting process begins when the screwdriver portion tip is engaged with the tappet screw 50, the pneumatic plug 114 is inserted in the spark plug opening 58, and the operator presses the start button 112. The process initiation portion 130 detects the pressing of the start button 112 (STEP 401). After the start button 112 has been pressed, the controller 108 begins the tappet clearance setting process by initiating the air flow (STEP 402).
The process initiation portion 130 receives the signal from the start button 112, and is electrically connected to the solenoid output 132. Through this electrical connection, the process initiation portion 130 sends a signal to the solenoid output 132. The solenoid output 132, in turn, is connected to and sends a signal to the solenoid relay 134. Upon receiving the signal, the solenoid relay 134 connects the power supply 136 to the electric solenoid valve 118 of the pneumatic portion 106.
Once the electric solenoid valve 118 is powered through the solenoid relay 134, the solenoid valve 118 opens and allows air to flow therethrough. As explained above, the electric solenoid valve 118 is disposed between the regulator 120 and the mass air flow meter 116. Thus, when the electric solenoid 118 is opened, the air flow being regulated by the regulator 120 is free to pass through the mass air flow meter 116, through the pneumatic plug 114, and into the cylinder via the spark plug opening 58.
The mass air flow meter 116 senses the air flow and outputs a voltage signal to the controller 108 that is proportional to the air flow to permit the controller 108 to monitor the air flow. The voltage signal is provided to the voltage input 138, which is connected to the voltage monitor 140. As the voltage output by the mass air flow meter 116 is proportional to the air flowing therethrough, variable air flows result in variable voltage output, while stable air flows result in stable voltage output. Accordingly, air flow is determined to be stable when the mass air flow meter 116 outputs a stable voltage to the controller 108. A stable voltage is defined as a condition wherein the detected voltage does not change for a predetermined period of time.
Once a stable air flow is detected, the controller 108 sends a signal to the tightening output 142, which instructs the screwdriver 110 to tighten the tappet screw 50. The screwdriver 110 then begins to rotate so as to tighten the tappet 50 (STEP 404), and thereby rotate the tappet screw 50 to effect a downward linear movement. The tappet screw 50 is tightened until it is determined, based upon monitored air flow, that the engine valve 22 has begun to open.
To detect opening of the engine valve 22, air flow through the cylinder is continually monitored by the mass air flow meter 116 and the controller 108, as described above. By monitoring the air flow, the controller 108 is able to detect whether the engine valve is open (STEP 405). The mass air flow meter 116 outputs a voltage proportional to the air flow to the voltage input 138. When the valve 22 is closed, the detected voltage is stable. During the initial stages of tappet screw 50 tightening in which the engagement end 54 of the tappet screw 50 moves linearly toward the engaged end of the valve stem 27, the engine valve 22 remains closed, and the monitored air flow (and corresponding detected voltage) will remain stable. Once the tappet screw 50 is tightened so as to first engage and then move the engine valve 22, the air flow and, hence, the detected voltage, will change. When the detected voltage changes, the controller 108 recognizes that the engine valve is open.
In response, the controller 108, via the reverse output 144, instructs the screwdriver 110 (STEP 406) to begin loosening the tappet screw 50. Loosening of the tappet screw 50 results in an upward linear movement of the tappet screw 50 and, thus, closing of the engine valve 22.
While the tappet screw 50 is loosened by the screwdriver 110, the controller 108 continues to monitor the air flow so as to determine when the engine valve 22 has closed. As will be appreciated from the foregoing discussion, as the tappet screw 50 is loosened, prior to the engine valve 22 being closed, the engine valve 22 is in a state of closing. During this period, the amount that the engine valve 22 is open is being continually reduced and, therefore, a variable volume of air passes through the cylinder, causing the voltage monitor 140 to detect a variable voltage. When the engine valve 22 is closed, the air flow and associated voltage becomes stable, and the controller 108 will determine that the engine valve is closed (STEP 407).
Upon stabilization of the detected voltage, the controller 108 will output a signal, via the reference output 146, to the screwdriver 110 to stop loosening the tappet screw 50 (STEP 408). It should be noted that at this point in the process, the tappet screw 50 is positioned so that the engine valve 22 has just closed. In this position, the engagement end 54 of the tappet screw 50 is abutting the engaged end of the valve stem 27, but is not applying enough force to overcome the spring bias of the valve assembly. This tappet screw 50 position is referred to herein as the reference position.
When the tappet is in the reference position, the reference output 146 sends the signal to the screwdriver to stop loosening and to begin the final rotation from the reference position, the controller 108 signals to the solenoid output 132 to switch the solenoid relay 134 away from providing power to the electric solenoid valve 118. This causes the solenoid relay 134 to switch from powering the electric solenoid valve 118, thereby de-energizing the electric solenoid valve 118. As the solenoid valve 118 is de-energized, the solenoid valve 118 returns to a state of blocking the air flow between the regulator 120 and the mass air flow meter 116. Consequently, the air valve is turned off (STEP 409).
Once the tappet screw 50 is in the reference position, as mentioned above, the tappet screw 50 is to be rotated, in a loosening direction, a predetermined number of degrees so as to set the tappet clearance. The predetermined number of degrees the tappet screw 50 is rotated from the reference position is determined experimentally. While the exact number of degrees of rotation from the reference position may vary, generally, the tappet clearance is between about 0.160 mm to 0.240 mm, and the tappet screw 50 (assuming a thread pitch of between about 0.75-1.0 threads/mm) should be rotated between about 80-90 degrees from the reference position.
To affect this final tappet screw 50 rotation, the reference output 146, in addition to instructing the screwdriver 110 to stop, also instructs the screwdriver 110 to rotate the tappet screw 50 the predetermined amount or number of degrees, thereby setting the final tappet clearance position. To ensure that the screwdriver 110 rotates the tappet screw 50 the appropriate amount or number of degrees, the time of energization of the screwdriver 110 is controlled. The screwdriver 110 is energized for the amount of time required to rotate the tappet screw 50 the appropriate amount or number of degrees.
The tappet nut 52 must be tightened without moving the tappet screw 50. To accomplish this, a wrench (not shown) engages the tappet nut 52, and tightens the tappet nut 52 while the screwdriver 110 continues to engage the tappet screw 50 to ensure that the tightening of the tappet nut 52 by the wrench does not move the tappet screw 50.
At this point, the process of setting tappet clearance is complete. The screwdriver portion 104 sends a signal to the controller 108 that the cycle is complete (STEP 410). The controller 108 then signals the shut-down output 148, which resets all inputs and outputs (STEP 411) and triggers a cycle completion relay 152 to switch power to the cycle complete light 150 (STEP 412).
The tappet setting device 102 is then reset and prepared to have the pneumatic portion 106 and the screwdriver portion 104 removed from the engine 100. Following removal of the screwdriver 110 and the pneumatic plug 114 from the engine 100, the tappet setting device 102 is ready for setting another tappet screw 50.
The tappet clearance setting method and device of the present invention offers many advantages over conventional methods of tappet clearance setting. Most importantly, the present device and method is capable of setting tappet clearance more accurately than conventional methods and devices. Further, the present invention also yields efficiency improvements, as the microprocessor based controller 108 can receive signals and give instructions much more efficiently than a human operator.
While the present invention has been described with particularity herein, it is considered apparent that the present invention is capable of numerous modifications, substitutions, and rearrangements of parts without departing from the scope and spirit of the present invention. Therefore, the invention is not to be limited to the particular preferred embodiments described hereinbefore, but rather only defined by the claims appended hereto.
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