Patent Application
20200173313
The disclosure relates to a hydraulic camshaft adjuster and to a method for producing a hydraulic camshaft adjuster.
Hydraulic camshaft adjusters are used in internal combustion engines in order to adapt a load state of the internal combustion engine and thus to increase the efficiency of the internal combustion engine. Hydraulic camshaft adjusters which operate on the rotary vane principle are known from the prior art. In terms of their basic construction, these camshaft adjusters generally have a stator, which can be driven by a crankshaft of an internal combustion engine, and a rotor, which is connected to the camshaft of the internal combustion engine for conjoint rotation therewith. Between the stator and the rotor there is an annular space which is divided by radially inward-pointing projections connected to the stator for conjoint rotation therewith into a plurality of working chambers, which are each divided by a vane pointing radially outward from the rotor into two pressure chambers. Depending on the supply of a hydraulic pressure medium to the pressure chambers, the position of the rotor relative to the stator and hence also the position of the camshaft relative to the crankshaft can be adjusted in the “advanced” or “retarded” direction. The prior art includes hydraulic camshaft adjusters that have a central locking system, in which the rotor can also be locked in a central position in addition to the respective end positions in order, in particular, to facilitate engine starting. In exceptional cases, however, e.g. in the case of stalling of the internal combustion engine, it is possible that the locking device will not lock the rotor correctly, and it will be necessary to operate the camshaft adjuster with an unlocked rotor in the subsequent starting phase. However, since some internal combustion engines have very poor starting behavior when the rotor is not locked in the central position, the rotor must then be automatically rotated into the central locking position and subsequently locked in the starting phase.
DE10 2012 211 870 A1 discloses a hydraulic camshaft adjuster having a central locking device. Here, the central locking device has a first and a second locking guide slot, wherein the first locking guide slot is formed on a first cover, and the second locking guide slot is formed on a second cover situated opposite the first cover, and the locking pins emerge at opposite ends of the rotor.
DE 10 2014 212 617 A1 discloses a hydraulic camshaft adjuster having a central locking function, wherein the rotor can be rotated out of any position into the central locking position according to the principle of a hydraulic ratchet, wherein a rotary motion counter to this rotation is locked. For this purpose, the hydraulic ratchet uses alternating torques of the camshaft drive in order to pull the rotor from an “advanced” position of adjustment or a “retarded” position of adjustment into the central position, depending on the initial position. To achieve this, one group of working chambers must in each case be closed in order to prevent rotation counter to the intended direction of rotation and to support the corresponding torques of the camshaft. In this case, the locking pins may be arranged either on different sides of the rotor or on the same side. DE 10 2007 004 196 discloses a locking cover having two stacked locking covers mounted on one side.
DE 10 2007 004 196 A1 shows a device for camshaft adjustment on an internal combustion engine, the device having an inner rotor which is connected to a camshaft for conjoint rotation therewith and can be rotatably adjusted relative to an outer rotor connected in terms of drive to a crankshaft. At least one hydraulic chamber delimited by side walls is introduced into the outer rotor. This chamber is divided by an element extending radially outwards from the inner rotor into two subchambers. To lock the relative motion between the inner rotor and the outer rotor, there are two locking pins which pass axially through the inner rotor and can engage in two apertures introduced into one of the side walls, the latter being designed as locking covers. The locking cover consists of two parts, wherein each of the parts has an aperture for the engagement of a respective locking pin.
DE 10 2013 223 301 A1 shows a camshaft adjusting device that has a stator, which can be connected to a crankshaft of an internal combustion engine, a rotor, which is mounted so as to be rotatable relative to the stator and can be connected to a camshaft, and a locking device for locking the rotor relative to the stator. The locking device has a locking guide slot produced by powder metallurgy, which is fixed relative to the stator or rotor, and at least one locking pin, which can be locked in the locking guide slot. The locking guide slot has a greater density in at least one section of the surface edge zone than the density of the basic material of the locking guide slot.
DE 10 2013 224 862 A1 shows a camshaft adjusting device that has a stator, which can be connected to a crankshaft of an internal combustion engine, a rotor, which is mounted so as to be rotatable relative to the stator and can be connected to a camshaft, and a locking device for locking the rotor relative to the stator. The locking device has a locking guide slot, which is fixed relative to the stator, and at least one locking pin, which is fixed relative to the rotor and can be locked in the locking guide slot. The locking guide slot is arranged in an at least two-part cover which is fixed relative to the stator and rests laterally against the rotor. The two parts of the cover can be fastened at different rotational angles relative to one another, wherein the locking guide slot is formed by at least one aperture provided in a first part of the cover, and a projection that engages in the aperture is provided on a second part of the cover.
DE 10 2016 218 793 A1 shows a camshaft adjuster having an input element and an output element that can be rotated within an angular range relative to the input element and can be connected to a camshaft. Pressurizable working chambers for the rotation of the input element relative to the output element are formed between the input element and the output element. The camshaft adjuster has a volume reservoir for collecting hydraulic medium, wherein the volume reservoir feeds the hydraulic medium via a check valve to a working chamber subject to a vacuum inasmuch as the vacuum in the working chamber opens the check valve. The check valve is arranged in an axial position between the working chamber and the volume reservoir, wherein the volume reservoir is formed by a cover element connected to the input element for conjoint rotation therewith.
The prior art furthermore includes a hydraulic camshaft adjuster that has a pressure medium reservoir and a “smart-phasing function”, in which the working chambers can draw in additional pressure medium from a reservoir in the event of an undersupply of pressure medium by the pressure medium pump in order to avoid drawing in air and an associated malfunction of the hydraulic camshaft adjuster.
The disadvantage here is that the functioning of a hydraulic ratchet depends heavily on the pressure medium supply and the viscosity of the pressure medium. At low temperatures, functioning may be restricted or may fail owing to the flow resistances, which are then high. In the case of a normal engine stop, this plays no role since the pressure medium is heated by the operation of the engine and has a low viscosity. If the motor is shut down without locking, e.g. due to stalling, the hydraulic camshaft adjuster should lock the internal combustion engine as a failsafe function when the engine is started. If the engine start takes place after prolonged cooling at a low ambient temperature, the hydraulic ratchet may fail and locking in the central locking position may not occur.
It is the object of the disclosure to develop a hydraulic camshaft adjuster with a smart phasing function in such a way that operationally reliable locking of the rotor in the central locking position takes place, irrespective of external conditions, and the disadvantages known from the prior art are overcome.
According to the disclosure, the object is achieved by a hydraulic camshaft adjuster for adjusting the timings of gas exchange valves of an internal combustion engine, having a stator, which is synchronously rotatable with a crankshaft of the internal combustion engine, and a rotor, which is arranged so as to be rotatable relative to the stator and is synchronously rotatable with a camshaft. The hydraulic camshaft adjuster furthermore has two groups of working chambers, which can each be supplied with a pressure medium flowing in or out in a pressure medium circuit and have a different direction of action. A central locking device for locking the rotor in a defined position relative to the stator is furthermore provided on the hydraulic camshaft adjuster. The stator is delimited at a first end by a multi-part locking cover, wherein the multi-part locking cover has a first locking cover and a second locking cover. In this arrangement, a first step of a mechanical ratchet is formed on the first locking cover, and at least one further step of the mechanical ratchet is formed on the second locking cover. It is thereby possible to form a mechanical ratchet mechanism which assists rotation of the rotor into the central locking position and thus makes the central locking function substantially independent of the viscosity of the pressure medium.
According to the disclosure, a check valve plate is arranged between the first locking cover and the second locking cover. The check valve plate is thereby protected by the hardened first locking cover from friction by the rotor and the locking pins, and a more advantageous arrangement of the check valve outlets is possible. The check valves allow an appropriate pressure medium supply to the working chambers, wherein, in the event of an undersupply to a working chamber and a reduced pressure resulting therefrom, the additional pressure medium can flow into the respective working chamber from a reservoir.
Advantageous improvements and developments of the hydraulic camshaft adjuster are possible by means of the features described herein.
In an example embodiment of the disclosure, it is envisaged that at least one insert is provided on the second locking cover, which insert can be brought into operative connection with a locking pin of the central locking device. Since the shock loads on the locking mechanism are high, it is worthwhile and expedient to reinforce the region of the locking guide slot on the second locking cover. This can be accomplished in a simple manner by means of an insert.
A stop for the locking pin can be formed on the insert. By means of a stop on the insert, the forces of the locking pin are transmitted only indirectly to the second locking cover, with the result that the mechanical load on the second locking cover remains relatively low. This allows simple and low-cost manufacture of the second locking cover since, in this case, easily machined materials and/or advantageous manufacturing methods can be employed.
In an example embodiment of the invention, it is envisaged that the step for the operation of the hydraulic ratchet is formed on the insert. As a result, the locking pin can be rotated in steps together with the rotor from its initial position into the central locking position. In addition, the forces during the latching in of the locking pin at the position of the axially extending stop surface of the step are absorbed by the insert, with the result that the load on the basic material of the second locking cover remains low and the risk of operationally induced material fatigue or of increased wear can be lowered.
It is envisaged that the insert can be composed of a harder and higher-strength material than the material of the second locking cover. By means of a hard and tough material for the insert, the wear on the central locking device can be lowered and the durability of the locking mechanism can be increased.
The insert can be composed of a sintered metal or produced by means of a fine blanking or extrusion method. By means of a high-strength sintered metal or a fine blanking or extrusion press for the insert, the strength of the second locking cover as a two-component part can be increased, wherein the region of the locking guide slot which is subject to high mechanical loads can be made correspondingly harder and more impact resistant. A steel, e.g. a C45 steel, can be provided as the material for a fine-blanked part, for example. A part composed of a 16MnCr5 steel is provided as an extruded part, for example, said part subsequently being hardened. The locking cover can be composed of a sintered metal, e.g. Sint-D11. As an alternative, it is also possible for the locking cover to be produced as a fine-blanked part composed of a steel such as C45, 16MnCr5 or S460MC, wherein the locking cover can furthermore additionally be hardened, thus making it possible to dispense with an insert and thus to reduce the outlay on assembly and the number of parts.
In an alternative embodiment of the invention, it is envisaged that the insert is pressed into a guide slot base of the central locking device on the second locking cover. In this case, a hard, impact-resistant insert can be pressed into the guide slot base of the central locking device on the second locking cover, and therefore the insert can also be embodied as a stamped, milled or turned part. By means of the press-fitting, a nonpositive and operationally reliable connection between the insert and the second locking cover is achieved.
The insert can be secured against tilting or falling out of the second locking cover by the check valve plate. As an alternative or in addition, the insert can be fixed on the second locking cover by means of a shoulder on the check valve plate or by bending over the check valve plate, with the result that the check valve plate serves as a means of securing the insert on the second locking cover.
As an alternative to a stepped insert, a formed check valve plate could also fix a simple, unstepped insert, optionally embodied as a stamping, in its position.
Furthermore, it is also possible to provide a plurality of inserts stacked one on top of the other instead of a single inserts, wherein a step can be formed by the differing geometry of the inserts. This enables the inserts to be embodied in a particularly simple and low-cost way as stampings.
A method for producing a hydraulic camshaft adjuster can have the following steps, wherein the stator is delimited at a first end by a multi-part locking cover, wherein a first step of a mechanical ratchet is formed on the first locking cover, and at least one further step of a mechanical ratchet is formed on the second locking cover, and wherein the hydraulic camshaft adjuster additionally has a hydraulic ratchet mechanism, by means of which the rotor is rotated into a central locking position. This makes it possible to produce a rotor for a hydraulic camshaft adjuster with central locking in which there are both a hydraulic ratchet and a mechanical ratchet, thus enabling the rotor to be rotated into the central locking position in a manner substantially independent of the viscosity of the pressure medium and facilitating locking in the central locking position. In this case, the mechanical ratchet and the hydraulic ratchet can contribute simultaneously to the adjustment of the rotor into the central locking position. The hydraulic ratchet acts when the outflow from the working chamber that pushes toward the central locking position is closed. The locking pin closes this outflow in the locked position. In the intermediate latching position of the mechanical ratchet, it continues to be held closed. Because of the locking depth, required for this purpose, through the first locking cover, it is advantageous if the insert is of stepped design.
Unless stated otherwise in individual cases, combining the various embodiments of the invention which are mentioned in the present application is an advantageous possibility.
The disclosure is explained in greater detail below by means of an illustrative embodiment and the associated drawings. Here, components that are the same or components with the same function are denoted by the same reference numerals. In the drawings:
The two-part locking cover 11, 12 of the central locking device 10 is illustrated on an enlarged scale in
A stepped insert 21 is shown in an enlarged illustration in
A segment of a hydraulic camshaft adjuster 1 is shown in a sectioned three-dimensional illustration in
Another segment of a hydraulic camshaft adjuster 1 is illustrated in
A third illustration of a segment of the hydraulic camshaft adjuster 1 is shown in
The functioning of the hydraulic ratchet mechanism depends on the oil supply and on the temperature-dependent viscosity of the pressure medium. At low temperatures, the functioning of the hydraulic ratchet mechanism can fail owing to the flow resistances, which are then high. This plays a role especially when an internal combustion engine is shut down unexpectedly, e.g. by stalling, shortly after a cold start, and the hydraulic camshaft adjuster 1 remains unlocked. If the engine is started with cold and thus viscous pressure medium, the hydraulic ratchet mechanism may fail. To cover a failsafe function of the hydraulic camshaft adjuster 1, an additional mechanical ratchet 23 is employed. This comprises a step in which the locking pin 17 can latch in between the end stop positions and the central locking position.
The mechanical ratchet 23 and the hydraulic ratchet can and should contribute simultaneously to the adjustment of the rotor 3 into the central locking position. The hydraulic ratchet acts when the outflow 29 from the working chamber 8, 9 that pushes toward the central position is closed. The locking pin 17 closes this outflow 29 in the locked position. In the intermediate latching position of the mechanical ratchet 23, it continues to be held closed. Because of the locking depth, required for this purpose, through the first locking cover 11, the insert 21 can be of stepped design, or a step 22 can be provided in some other way. The insert 21 in the second locking cover 12 is no longer secured axially against tilting due to shock loads by the extended locking guide slot and the aperture for the connection of the pressure medium supply for hydraulic unlocking of the central locking device 10 in the first locking cover 11. The check valve plate 16 situated between the first locking cover 11 and the second locking cover 12 is therefore used as a securing means.
In the example embodiment illustrated, the mechanical ratchet 23 is formed only in the “retarded” direction of adjustment from the center and not in the “advanced” direction of adjustment since in this case no spiral spring is employed to compensate the camshaft friction torque. For adjustment out of the “advanced” direction of adjustment into the central locking position, the corresponding camshaft friction torque can exert a supportive effect, with the result that no additional mechanical ratchet 23 is required in this direction. In principle, the mechanical ratchet 23 can also be formed in both directions of adjustment and thus on both sides of the central locking position. In this case, an additional stepped insert 21 can be provided and inserted into the second locking cover 12. If the additional mechanical ratchet is used on the same locking pin 17 as the mechanical ratchet 23 illustrated in the embodiment example, the stepped insert should produce a reverse switching logic for the hydraulic ratchet mechanism, with the result that the hydraulic connection 29 to the working chambers 8, 9 is held open in the intermediate latching position. A mechanical ratchet 23 having a plurality of steps and finer gradation associated therewith is furthermore conceivable, wherein a multiple-step insert 21 can be used for this purpose.
In the case of a hydraulic camshaft adjuster 1 according to the disclosure, it is thus possible to improve the rotation of the rotor 3 into the central locking position even at a low temperature and a high viscosity of the pressure medium and thus to ensure operationally reliable locking in the central locking position, irrespective of the external boundary conditions.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2017 117 943.7 | Aug 2017 | DE | national |
This application is the U.S. National Phase of PCT Application No. PCT/DE2018/100674 filed on Aug. 1, 2018 which claims priority to DE 10 2017 117 943.7 filed on Aug. 8, 2017, the entire disclosures of which are incorporated by reference herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/DE2018/100674 | 8/1/2018 | WO | 00 |
