Internal sensing passage in an exhaust gas recirculation module

Information

  • Patent Grant
  • 6170476
  • Patent Number
    6,170,476
  • Date Filed
    Wednesday, November 25, 1998
    26 years ago
  • Date Issued
    Tuesday, January 9, 2001
    23 years ago
Abstract
An electric EGR module has a main flow passage containing a valve member operated by a movable actuator wall of a fluid pressure actuator to control exhaust gas flow through the passage. The movable actuator wall bounds a portion of a variable volume chamber space to which regulated vacuum from an electric vacuum regulator (EVR) valve is communicated to position the movable actuator wall, and hence the valve member. An internal pressure sensing passage, which includes a tube that also functions as a shaft for coupling motion of the actuator wall to the valve member, communicates pressure at one side of an orifice in the main flow passage to a pressure sensor. The tube communicates with a variable volume chamber space that forms a portion of the sensing passage and that varies in volume with the positioning of the tube by the actuator wall. The pressure sensor and the EVR valve are integrated with the body of the fluid pressure actuator.
Description




FIELD OF THE INVENTION




This invention relates generally to automotive emission control valves, such as exhaust gas recirculation (EGR) valves that are used in exhaust emission control systems of automotive vehicle internal combustion engines. More specifically, the invention relates to the integration of a sensor, a fluid pressure regulator valve, and a fluid-pressure-operated actuator in an EGR valve to create an EGR module, hereinafter sometimes referred to as a “Modular EGR”.




BACKGROUND OF THE INVENTION




U.S. Pat. Nos. 5,241,940 (Gates, Jr.) and 5,613,479 (Gates et al.), which are hereby incorporated by reference, disclose EGR systems of the type in which a module that embodies principles of the present invention is useful.




SUMMARY OF THE INVENTION




The inventive module possesses a novel construction that provides important economic and functional advantages relating to fabrication, assembly, testing, installation, and use.




One generic aspect of the invention relates to an automotive emission control module comprising: an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting flow between the ports, an actuator for operating the valve, a pressure sensor having first and second pressure sensing ports, and first and second pressure sensing passages communicating the first and second pressure sensing ports to the main flow passage for sensing pressure differential along a portion of the length of the flow passage, the second pressure sensing passage extending through the actuator and comprising a chamber space that is disposed between the actuator and the pressure sensor.




Within this one generic aspect, some of the more specific aspects relate to the actuator comprising a shaft for operating the valve and an actuator body that contains two chamber spaces separated by a movable actuator wall that operates the shaft; the actuator body mounting on the emission control valve body, and the chamber space being arranged in axial succession along an axis of the module beyond the actuator relative to the valve; a separator wall separating the chamber space from the actuator, wherein the separator wall comprises an annulus having an inner margin sealed to an outside diameter of the shaft and an outer margin sealed to the actuator body; the inner margin of the separator wall annulus moving with the shaft; the actuator comprising a movable actuator wall dividing the actuator into two variable volume chamber spaces, and a spring being disposed within one of the two actuator chamber spaces to urge the valve toward closing the main flow passage; the actuator comprising an actuator body that mounts on the emission control valve body, and the second pressure sensing passage being internal to both the emission control valve body and the actuator body; including an orifice disposed in the main flow path between the first port and the valve for creating pressure differential between the first and second pressure sensing passages, and in which the first pressure sensing passage comprises a hole that extends through a wall of the emission control valve body circumscribing a location in the main flow passage that is between the first port and the orifice, and further including a tube extending from the hole external to the emission control valve body.




Still more of these more specific aspects relate to: the inclusion of a pressure regulating valve that comprises a source pressure port and a regulated pressure port and that, in accordance with a regulation signal, modulates source pressure at the source pressure port to a regulated pressure at the regulated pressure port, and in which the first pressure sensing passage communicates the first port to the source pressure port of the pressure regulating valve, and the regulated pressure port of the pressure regulating valve communicates with the actuator; the actuator comprising a shaft for operating the valve and two chamber spaces separated by a movable actuator wall that operates the shaft, the regulated pressure port of the pressure regulating valve communicating with one of the two chamber spaces of the actuator, and the other chamber space of the actuator communicating with atmosphere; the second pressure sensing passage comprising a chamber space arranged in axial succession with the actuator chamber spaces along an axis of the module, and the chamber space of the second pressure sensing passage being disposed axially beyond the two actuator chamber spaces relative to the valve; a separator wall dividing the chamber space of the second pressure sensing passage from the one chamber space of the actuator and comprising an annulus having an inner margin sealed to an outside diameter of the shaft and an outer margin sealed to a body of the actuator; the inclusion of an orifice disposed in the main flow path between the first port and the valve for creating pressure differential between the first and second pressure sensing passages, and in which the shaft comprises a tube, the valve comprises a stem extending from a head, one end of the tube is telescopically engaged with a free end of the stem, and the chamber space communicates via the tube and the stem with a location in the main flow passage that is between the first port and the orifice; and the chamber space communicating with the location in the main flow passage that is between the first port and the orifice via an opening in a side wall of the tube that is unoccluded by the telescopic engagement of the one tube end with the free end of the stem.




A further generic aspect relates to an automotive emission control module comprising: an emission control valve body having an internal main flow passage, a valve for selectively restricting the flow passage, an actuator comprising an actuator mechanism for operating the valve, a pressure sensor that provides a signal related to pressure communicated to the pressure sensor, and a pressure sensing passage communicating pressure to the pressure sensor from a location in the main flow passage, the pressure sensing passage including a variable volume chamber space which is external to the actuator mechanism, and the volume of which varies with the operation of the valve by the actuator mechanism.




Within this further generic aspect, more specific aspects relate to: the actuator mechanism comprising two chamber spaces separated by a movable actuator wall that operates the valve, and all three chamber spaces being disposed in axial succession along an axis of the module; the variable volume chamber space being disposed axially beyond the two chamber spaces of the actuator mechanism relative to the valve; the actuator mechanism comprising a movable actuator wall that divides the two chamber spaces of the actuator mechanism and that operates the valve via a tube which forms a portion of the pressure sensing passage; a spring being disposed within one of the chamber spaces of the actuator mechanism and acting on the movable actuator wall to urge the valve head toward seating on a valve seat; and a movable separator wall divides the variable volume chamber space from one of the two chamber spaces of the actuator mechanism and comprises an annulus having an inner margin sealed to an outside diameter of the tube and an outer margin sealed to a body of the actuator that contains the actuator mechanism.




Still another generic aspect relates to an automotive emission control module comprising: an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting the flow passage, an actuator, comprising an actuator body mounted on the emission control valve body, for operating the valve, an electric pressure sensor mounted on the actuator body and having a pressure sensing port ported to the main flow passage, an electric-operated fluid pressure regulator valve mounted on the actuator body for providing regulated fluid pressure to operate the actuator, one of the pressure sensor and the actuator body comprising a nipple that is telescopically received in a hole in the other of the pressure sensor and the actuator body to form a portion of a pressure sensing passage through which the pressure sensing port is ported to the main flow passage, the actuator comprising a shaft that is positionable along an axis to operate the valve, and the hole and nipple are coaxial with the axis. A more specific aspect relates to the pressure sensing passage comprising a chamber space separated from the actuator by a movable separator wall that moves with the shaft, the pressure sensing passage including a hole extending through the shaft providing communication between the chamber space and the main flow passage, and the nipple providing communication of the chamber space to the pressure sensing port of the sensor.











BRIEF DESCRIPTION OF THE DRAWINGS




The accompanying drawings, which are incorporated herein and constitute part of this specification, include one or more presently preferred embodiments of the invention, and together with a general description given above and a detailed description given below, serve to disclose principles of the invention in accordance with a best mode contemplated for carrying out the invention.





FIG. 1

is a front elevation view, partly in cross section, of an exemplary module embodying principles of the present invention.





FIG. 2

is a full left side view in the direction of arrows


2





2


in FIG.


1


.





FIG. 3

is a full top plan view in the direction of arrows


3





3


in FIG.


1


.





FIG. 4

is view similar to

FIG. 1

showing a second exemplary module embodying principles of the present invention.





FIG. 5

is a perspective view, partly broken away, of the

FIG. 4

embodiment.





FIG. 6

is a fragmentary view looking in the general direction of arrow


6


in

FIG. 5

with portions sectioned away.





FIG. 7

is a view similar to

FIG. 1

showing a third exemplary module embodying principles of the present invention.











DESCRIPTION OF THE PREFERRED EMBODIMENT




FIGS.


1


-


3


disclose a module


20


embodying principles of the invention and comprising an emission control valve body


22


, a fluid-pressure-operated actuator


24


, an electric-operated pressure regulator valve


26


, and a sensor


28


. Because incorporation of the inventive module


20


in EGR systems as described in the aforementioned “Gates” patents involves the use of engine induction system vacuum, i.e. negative pressure, valve


26


is an electric-operated vacuum regulator valve, sometimes referred to as an EVR valve, and sensor


28


is a pressure sensor that provides an electric signal related to the magnitude of sensed vacuum.




Valve body


22


comprises an internal main flow passage


30


extending between a first port


32


and a second port


34


. An annular valve seat element


36


is disposed in valve body


22


to provide an annular seat surface


38


circumscribing a transverse cross-sectional area of passage


30


. A valve member


40


comprising a non-flow-through valve head


42


is disposed within body


22


coaxially with an imaginary axis


44


. Valve head


42


is shown seated on seat surface


38


closing passage


30


to flow between ports


32


and


34


.




A hollow tube


46


is disposed coaxially with axis


44


. One end of tube


46


is diametrically enlarged to telescopically overlap and join with a stem


48


of valve member


40


so that tube


46


functions as a shaft for operating valve member


40


. Stem


48


comprises a central axial blind hole


50


and several radial holes


54


intersecting hole


50


to provide for the interior of tube


46


to communicate with passage


30


. A bushing


56


is fitted to valve body


22


and comprises a central through-hole


58


providing axial guidance for motion of tube


46


along axis


44


. Bushing


56


also captures the outer margin of a circular flange of a generally cylindrical walled metal shield


60


on an internal shoulder


62


of valve body


22


. Shield


60


surrounds a portion of tube


46


that protrudes from through-hole


58


. An orifice member


64


comprising an orifice


66


is wedged within passage


30


between port


32


and seat element


36


such that flow through main passage


30


is constrained to pass through orifice


66


.




Fluid-pressure-operated actuator


24


comprises a body


68


that is in assembly with valve body


22


coaxial with axis


44


. Actuator body


68


comprises a first body part


70


and a second body part


72


. Body part


72


comprises sheet metal formed to a generally circular shape having a central through-hole


74


that allows the part to fit over an end of bushing


56


that protrudes beyond a flange


76


of body


22


. An annular gasket


78


is sandwiched between body part


72


and flange


76


. Each of body part


72


, gasket


78


, and flange


76


contains a like hole pattern that provides for the secure attachment of body part


72


to valve body


22


by headed screws


79


whose threaded shanks are passed through aligned holes in part


72


and gasket


78


and tightened in threaded holes in flange


76


.




Body


68


comprises an interior that is divided into two chamber spaces


80


,


82


by a movable actuator wall


84


. Movable actuator wall


84


comprises an inner formed metal part


86


and an outer flexible part


88


. Part


88


has a circular annular shape including a convolution


88




c


that rolls as wall


84


moves. Part


88


also has a bead


90


extending continuously around its outer margin. The outer margin of actuator body part


70


comprises a shoulder


92


, and bead


90


is held compressed between parts


70


and


72


by an outer margin


93


of body part


72


being folded around and crimped against shoulder


92


, thereby securing parts


70


,


72


, and


88


in assembly and sealing the outer perimeters of chamber spaces


80


and


82


. The inner margin of part


88


is insert-molded onto the outer margin of part


86


to create a fluid-tight joint uniting the two parts.




Part


86


is constructed to provide a seat


94


for seating an axial end of a helical coil compression spring


96


that is disposed within chamber space


80


. Body part


70


comprises a central tower


98


proximate the end of which is an integral circular wall


100


that provides an internal circular groove


102


for seating the opposite end of spring


96


. In this way spring


96


acts to bias movable wall


84


axially toward valve seat surface


38


. Part


86


further comprises a central flanged hole


104


through which tube


46


passes and to which tube


46


has fluid-tight attachment. Accordingly, the biasing of wall


84


by spring


96


acts via tube


46


to urge valve head


42


toward seating on seat surface


38


, and thereby closing passage


30


to flow between ports


32


and


34


.




The actuator body further includes a cap


106


that is mounted atop tower


98


to close the otherwise open end of part


70


. Cap


106


is in assembly with part


70


and comprises a rim


107


that forces a sealing bead


109


of a movable separator wall


110


against wall


100


. Wall


110


is a flexible part having bead


109


extending around its outer margin, a bead


112


around its inner margin, and a rolling convolution between its inner and outer margins. Bead


112


is held fluid-tight on tube


46


between a sleeve


114


that is fitted onto tube


46


below bead


112


and a washer


116


that is fitted onto tube


46


above the bead. Cap


106


and wall


110


thereby cooperatively define a third chamber space


118


that is consecutive along axis


44


to chamber spaces


80


and


82


and separated from chamber space


80


by wall


110


. The end of tube


46


disposed within chamber space


118


is open, thereby placing the interior of the former in communication with the latter. Because the convolution of separator wall


110


rolls as the central region of the wall is moved by tube


46


, the volume of chamber space


118


varies with the movement imparted to tube


46


by actuator


24


.




EVR valve


26


has an imaginary longitudinal axis


120


that is disposed orthogonal to a plane containing axis


44


. Valve


26


comprises an atmospheric inlet port


122


for communication to atmosphere, a source vacuum inlet port


124


for communication to engine intake system vacuum, and a regulated vacuum outlet port


126


. Because port


30


is communicated to intake system vacuum when, module


20


is in use, that vacuum can be conveniently communicated to port


124


by a tap


127


into body


22


immediately adjacent port


30


before orifice


66


and a C-shaped hose


128


having one end fitted over an exterior end of tap


127


and another end fitted over a nipple that forms source vacuum inlet port


124


in the illustrated embodiment.




EVR valve


26


comprises an enclosure, or body,


190


having a cylindrical side wall


189


and containing an internal regulating mechanism like that of the EVR valves described in U.S. Pat. No. 5,448,981, which is incorporated herein by reference. Atmospheric inlet port


122


communicates to atmosphere through a particulate filter


129


contained within an interior space at one axial end of enclosure


190


. Enclosure


190


comprises an end cap


191


fitted over filter


129


at that one axial end. Within an opposite axial end of the enclosure is a regulated vacuum chamber space


130


. A helical coil compression spring


134


is disposed within chamber space


130


to bias a valve disk


136


toward seating on a valve seat


138


at an end of a passage


140


that is coaxial with axis


120


and leads to atmospheric port


122


. When seated, valve disk


136


closes passage


140


, blocking communication between chamber space


130


and atmosphere.




Proximately adjacent chamber space


130


, an end wall


192


of enclosure


190


contains a passageway


142


that is transverse to axis


120


and forms a continuation of the passage through the nipple forming port


124


. Communication between chamber space


130


and passageway


142


is through an orifice


144


that is integrally formed in end wall


190


coaxial with axis


120


.




The internal mechanism of EVR valve


26


further comprises a solenoid


145


that is operated by pulse width modulation. The pulse width modulation of the solenoid modulates disk


136


to correspondingly modulate the bleeding of vacuum from chamber space


130


and through passage


140


to atmosphere. A pulse width modulated electric signal applied to solenoid


145


causes the vacuum in chamber space


130


to be regulated in accordance with the degree of signal modulation within a range that extends essentially from full intake system vacuum applied at vacuum inlet port


124


to essentially atmospheric pressure applied at atmospheric inlet port


122


.




A further internal passage


146


extends from regulated vacuum outlet port


126


to actuator chamber space


80


to place the latter in fluid communication with chamber space


130


. In this way, the vacuum in chamber space


80


is regulated in accordance with the pulse-width-modulated electric signal that operates valve


26


.




Passageway


142


also serves to pass intake system vacuum to a pressure sensing port


150


of sensor


28


. This is accomplished through a tube


152


extending between port


150


and a location on EVR valve


26


diametrically opposite the nipple forming port


124


. Tube


152


may be embodied as part of the body of sensor


28


, fitting into a counterbore in EVR valve


26


at the end of passage


172


. The end portion of tube


152


comprises an


0


-ring


154


seated in an external circular groove to provide a fluid-tight radial seal of the tube's O.D. to the I.D. of the counterbore.




Sensor


28


comprises a second pressure sensing port


156


that is communicated to chamber space


118


. A frustoconical shaped wall of cap


106


contains a local formation


158


that provides a tap to chamber space


118


. A tube


160


, which like tube


152


may be embodied as a part of the pressure sensor body, is disposed to extend from the sensor body parallel to tube


152


for communicating port


156


with the tap into chamber space


118


. The end portion of tube


160


comprises an O-ring


162


seated in an external circular groove to provide a fluid-tight radial seal of the tube's O.D. to the I.D. of a hole that extends through the wall of formation


158


.




The organization and arrangement that has been described therefore provides first and second pressure sensing passages. The first pressure sensing passage extends from port


32


through tap


127


, hose


128


, passageway


142


, and tube


152


to sensing port


150


. The second pressure sensing passage extends from main flow passage


30


at a location between orifice


66


and valve seat


38


, through stem


48


of valve member


40


, through tube


46


, through chamber space


118


, through formation


158


, and through tube


160


to sensing port


156


. In this way sensor


28


can sense pressure differential across orifice


66


.




An electric connector


164


provides for sensor


28


and EVR valve


26


to be connected with an electric control circuit (not shown). Connector


164


contains five one-piece, stamped metal, terminals, three of which,


166


,


168


,


170


, are associated with sensor


28


and two of which,


172


,


174


, with EVR valve


26


. Connector


164


comprises a surround


176


that forms part of the body of sensor


28


. Surround


176


laterally bounds free ends of all five terminals


166


,


168


,


170


,


172


,


174


. Terminals


166


,


168


,


170


extend into the sensor body from their free ends that are within surround


176


to connect to respective sensor element leads. Terminals


172


,


174


extend through the sensor body from the free ends that are within surround


176


to opposite free ends arranged in a fixed terminal end pattern. There they make mating connection with similarly arranged terminal ends of terminals of EVR valve


26


upon assembly of sensor


28


and valve


26


together. Such assembly comprises aligning tube


152


with hole


154


, aligning tube


160


with hole


162


, and aligning terminals of EVR valve


26


with corresponding terminals carried by sensor


28


, and then advancing the sensor and EVR valve toward each other.




Hence, when connector


164


is connected with a mating connector (not shown) of electric circuitry that operates module


20


, electric terminals


172


,


174


carry pulse width modulated current to solenoid


145


, and terminals


166


,


168


,


170


carry electric current signals related to pressures sensed at sensor ports


150


,


156


.




An important aspect of the integration of EVR valve


26


and actuator


24


in module


20


relates to fabricating enclosure


190


and actuator body part


70


as a single polymeric part. Side wall


189


and end wall


192


of enclosure


190


, and actuator body part


70


, are embodied in a single polymeric part which includes internal passage


146


extending from regulated vacuum outlet port


126


to actuator chamber space


80


to place the latter in fluid communication with chamber space


130


so that vacuum in chamber space


80


is regulated in accordance with the pulse-width-modulated electric signal that operates valve


26


.





FIGS. 4

,


5


, and


6


show an embodiment of valve


20


′ in which component parts corresponding to parts of valve


20


already described are identified by like reference numerals. While the general organization and arrangement of valve


20


′ is like that of valve


20


, several prime-numbered parts, including the following, differ in certain details from their unprime-numbered counterparts: actuator body part


70


′; EVR valve


26


′; pressure sensor


28


′; electric connector


164


′; cap


106


′; valve member


40


′; tube


46


′; movable actuator wall


84


′; and movable separator wall


110


′, for examples.




EVR valve


26


′ has its atmospheric inlet port


122


′ open to a somewhat semi-circularly shaped space that is enclosed by filter


129


′ and by the mounting of sensor


28


′ on actuator


24


′. Filter


129


′ is also enclosed by the mounting of sensor


28


′ and has a somewhat semi-circular shape that surrounds the open space to which atmospheric inlet port


122


′ is communicated. The body of sensor


28


′ includes a somewhat semi-circular shaped skirt


180


′ that provides a downright side wall spaced slightly outwardly of a somewhat semicircular outer surface of filter


129


′. Actuator body part


70


′ has an upright rim


182


′ that contains a series of through-holes


184


′. Air can enter via these through-holes to the space between the inside wall surface of skirt


180


′ and the radially outer surface of filter


129


′. In this way, the semi-circular circumferential extent of filter


129


′ about axis


44


′ provides an ample surface area for filtration of air without significant restriction before the air can enter port


122


′. The filter is preferably constructed to minimize pressure drop across it and to distribute the airstream passing through it as uniformly as possible so as to avoid the creation of “hot spots”.




The lower edge of skirt


180


′ has a groove


186


′ that fits onto the upper edge of rim


182


′ when the skirt and rim are in assembly relationship. From the base of tower


98


′, the wall of part


70


′ declines toward through-holes


184


′ to provide a declined surface for gravity drainage of any liquid that may accumulate within space enclosed by the mounting of sensor


28


′ on actuator


24


′. Filter


129


′ and skirt


180


′ have a circumferential co-extent that is circular for less than 360° about axis


44


′. Beyond this approximately semi-circular co-extent, both the filter and the body of sensor


28


′ are shaped to fit to external surfaces of actuator body part


70


′ and/or EVR valve enclosure


190


′ in fluid-tight manner that may include a suitable seal. For example, from generally diametrically opposite ends of its semi-circular extent, the skirt may continue more or less chordally relative to axis


44


′ so as to lie in a plane generally parallel to axis


120


′ and for the most part close against actuator body part


70


′ except for a notch that fits onto a projecting portion of the EVR enclosure that projects away from axis


120


′ and contains electric terminals


156


′ and


158


′ and port


122


′.




The body of sensor


28


′ serves purposes that are additional to the purpose of forming a cover that fits onto the actuator. It houses pressure sensing elements that supply electric signals related to pressures sensed at its ports; it also integrates electric connector


164


′. Four terminals


166


′,


168


′,


170


′, and


139


′ of connector


164


′ extend within the sensor body from a surround


176


′ to make electric connections with respective leads of sensor elements of sensor


28


′. Two terminals


172


′,


174


′ of connector


164


′ have right-angle shapes and extend within the sensor body from surround


176


′ to terminate in forked ends


172


A′,


174


A′ that make connection to respective blade terminals


156


′,


158


′ that are part of EVR valve


26


′. Hence, electric connections for both EVR valve


26


′ and pressure sensor


28


′ are embodied in a single connector


164


′.




Like actuator body part


70


and wall portions


189


,


192


of enclosure


190


, actuator body part


70


′ and wall portions


189


′,


192


′ of EVR valve


26


′ are embodied in a single part of homogeneous material throughout, such as a polymeric (plastic) part fabricated by injection molding. Internal mechanism of valve


26


′ is assembled into enclosure


190


′ through an opening at the opposite axial end of side wall


189


′ which is thereafter closed by an end cap


191


′. The single polymeric part that integrates enclosure


190


′ and actuator body part


70


′ also contains an internal passage


146


′ that communicates regulated vacuum port


126


′ of EVR valve


26


′ to chamber space


80


′ of actuator


24


′. Intake system vacuum is communicated through tap


127


′ and hose


128


′ to a vacuum inlet port


124


′ in end wall


192


′ centered on axis


120


′. Within enclosure


190


′ just inside end wall


192


′ is an arrangement that is analogous to that described for module


20


. That arrangement is shown in FIG.


6


.




The integration of various parts with pressure sensor


28


′ provides a unit that is assembled to body


68


′ of actuator


24


′. Such assembly comprises aligning that unit with the exterior of part


70


′, and then advancing the unit to essentially concurrently seat groove


186


′ on the edge of rim


182


′, lodge the end of a nipple


196


′ into sealed fit with an O-ring-containing hole


198


′ in cap


106


′, and engage the forked ends


172


A′,


174


A′ of terminals


172


′,


174


′ with blade terminals


156


′,


158


′.




A further difference in module


20


′ is that stem


48


′ contains no portion of the sensing passage that extends through the interior of tube


46


′. Just beyond the end of stem


48


′ the side wall of tube


46


′ has several through-holes


47


′ that communicate the interior of the tube to main passage


30


′. Shield


60


′ axially overlaps these through-holes for all operating positions of tube


46


′.





FIG. 7

discloses an embodiment of module


20


″ in which component parts corresponding to parts of module


20


′ are identified by like reference numerals, except double primed. The general organization and arrangement of module


20


″ is like that of module


20


′, except that actuator


24


″ and those parts mounted on actuator body part


70


″ are disposed 90° about axis


44


″ from the disposition in module


20


′, and the tap for supplying intake system vacuum to port


32


″ has been relocated.




In use of any of EGR modules


20


,


20


′, and


20


″, port


34


,


34


′,


34


″ is communicated to engine exhaust gas and port


32


,


32


′,


32


″ to engine intake system vacuum, such as intake manifold vacuum. For mounting of any of the valves, valve body


22


,


22


′,


22


″ may include a respective mounting flange


23


,


23


′,


23


″ that contains multiple holes for fastening the valve by means of fasteners.




Each of valves


20


,


20


′, and


20


″ may function in the manner described in either of the above referenced U.S. Pat. Nos. 5,241,940 (Gates, Jr.) and 5,613,479 (Gates et al.). Briefly, control of exhaust gas flow through main passage


30


,


30


′,


30


″ is accomplished by operating the EVR valve


26


,


26


′,


26


″ to cause the pressure differential across movable actuator wall


84


,


84


′,


84


″ to position valve head


40


,


40


′,


40


″ to regulate the pressure differential across orifice


66


,


66


′,


66


″ in a desired manner for particular engine operating conditions. Chamber space


82


,


82


′,


82


″ is communicated to atmosphere, such as by one or more openings through the wall of part


72


,


72


′,


72


″ adjacent flange


23


,


23


′,


23


″. Because orifice


66


,


66


′,


66


″ possesses an inherent pressure drop vs. flow characteristic, control of the pressure differential across it will inherently control flow through the EGR valve.




The disclosed EGR valves are advantageous for a number of reasons. Because sensing of pressure between a valve seat surface


38


,


38


′, and


38


″ and a respective orifice


66


,


66


′, and


66


″ occurs internally of the EGR valve, no external passage for such sensing is required. It is believed that the integration of various of parts with sensor


28


,


28


′,


28


″ and with actuator body part


70


,


70


′ and


70


″ can provide significant advantages in fabrication, assembly, and testing procedures. Such integration comprises various possibilities additional to those already mentioned.




Any of the EVR valve enclosure, the pressure sensor body, and the fluid pressure actuator body may be a piece that is fabricated by itself, and subsequently assembled to the others. Such assembly steps may comprises the use of separate and/or integrated fastening devices. Examples of separate fastening devices include devices such as screws and rivets. Examples of integrated fastening devices include tongue and groove connections, press-fit connections, and snap-catches.




The method of fabrication of modules


20


,


20


′, and


20


″ is the subject of co-pending patent application Ser. No. 09/199,185, METHOD OF MAKING AN AUTOMOTIVE EMISSION CONTROL MODULE HAVING FLUID-POWER-OPERATED ACTUATOR, FLUID PRESSURE REGULATOR VALVE, AND SENSOR, pending, which is incorporated in entirety herein by reference. Various other inventive aspects may be found in the following commonly assigned, co-pending, non-provisional patent applications that are also incorporated in their entirety herein by reference: Ser. No. 09/199,183, INTEGRATION OF SENSOR, ACTUATOR, AND REGULATOR VALVE IN AN EMISSION CONTROL MODULE, pending; Ser. No. 09/199,184, CALIBRATION AND TESTING OF AN AUTOMOTIVE EMISSION CONTROL MODULE, pending; and Ser. No. 09/199,186, AUTOMOTIVE VEHICLE HAVING A NOVEL EXHAUST GAS RECIRCULATION MODULE, pending.




It is to be understood that because the invention may be practiced in various forms within the scope of the appended claims, certain specific words and phrases that may be used to describe a particular exemplary embodiment of the invention are not intended to necessarily limit the scope of the invention solely on account of such use.



Claims
  • 1. An automotive emission control module, comprising:an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting flow between the ports, an actuator for operating the valve, a pressure sensor having first and second pressure sensing ports, first and second pressure sensing passages communicating the first and second pressure sensing ports to the main flow passage for sensing pressure differential along a portion of the length of the flow passage, the second pressure sensing passage extending through the actuator and including a chamber space that is disposed between the actuator and the pressure sensor, an orifice disposed in the main flow path between the first port and the valve for creating pressure differential between the first and second pressure sensing passages, the first pressure sensing passage including a hole extending through a wall of the emission control valve body circumscribing a location in the main flow passage that is between the first port and the orifice, and a tube extending from the hole external to the emission control valve body.
  • 2. An automotive emission control module, comprising:an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting flow between the ports, an actuator for operating the valve, a pressure sensor having first and second pressure sensing ports, and first and second pressure sensing passages communicating the first and second pressure sensing ports to the main flow passage for sensing pressure differential along a portion of the length of the flow passage, the second pressure sensing passage extending through the actuator and comprising a chamber space that is disposed between the actuator and the pressure sensor, and an orifice disposed in the main flow path between the first port and the valve and creating a pressure differential between the first and second pressure sensing passages, the shaft including a tube, the valve including a stem extending from a head, and one end of the tube telescopically engaging a free end of the stem, and the chamber space communicating via the tube and the stem with a location in the main flow passage that is between the first port and the orifice.
  • 3. An automotive emission control module, comprising:an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting flow between the ports, an actuator for operating the valve, a pressure sensor having first and second pressure sensing ports, and first and second pressure sensing passages communicating the first and second pressure sensing ports to the main flow passage for sensing pressure differential along a portion of the length of the flow passage, the second pressure sensing passage extending through the actuator and comprising a chamber space that is disposed between the actuator and the pressure sensor, and an orifice disposed in the main flow path between the first port and the valve and creating a pressure differential between the first and second pressure sensing passages, the shaft comprising a tube, the valve member including a stem extending from a valve head, and one end of the tube telescopically engaging a free end of the stem, and the chamber space communicating with a location in the main flow passage that is between the first port and the orifice via an opening in a side wall of the tube that is unoccluded by the telescopic engagement of the one tube end with the free end of the stem.
  • 4. An automotive emission control module comprising:an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting the flow passage, an actuator, comprising an actuator body mounted on the emission control valve body, for operating the valve, an electric pressure sensor mounted on the actuator body and having a pressure sensing port ported to the main flow passage, an electric-operated fluid pressure regulator valve mounted on the actuator body for providing regulated fluid pressure to operate the actuator, one of the pressure sensor and the actuator body comprising a nipple that is telescopically received in a hole in the other of the pressure sensor and the actuator body to form a portion of a pressure sensing passage through which the pressure sensing port is ported to the main flow passage, the actuator comprising a shaft that is positionable along an axis to operate the valve, and the hole and nipple are coaxial with the axis.
  • 5. An automotive emission control valve as set forth in claim 4 in which the pressure sensing passage comprises a chamber space separated from the actuator by a movable separator wall that moves with the shaft, the pressure sensing passage includes a hole extending through the shaft providing communication between the chamber space and the main flow passage, and the nipple provides communication of the chamber space to the pressure sensing port of the sensor.
  • 6. An automotive emission control module, comprising:an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting flow between the ports, an actuator including a shaft operatively connected to the valve and an actuator body defining two chamber spaces separated by a movable actuator wall operatively connected to the shaft, a pressure sensor having first and second pressure sensing ports, first and second pressure sensing passages communicating the first and second pressure sensing ports to the main flow passage for sensing pressure differential along a portion of the length of the flow passage, the second pressure sensing passage extending through the actuator and comprising a chamber space that is disposed between the actuator and the pressure sensor, and a separator wall separating the chamber space of the second pressure sensing passage from the actuator, the separator wall including an annulus having an inner margin sealed to an outside diameter of the shaft and an outer margin sealed to the actuator body.
  • 7. An automotive emission control module as set forth in claim 1 in which the actuator body mounts on the emission control valve body, and the chamber space is arranged in axial succession along an axis of the module beyond the actuator relative to the valve.
  • 8. An automotive emission control module as set forth in claim 1 in which the inner margin of the separator wall annulus moves with the shaft.
  • 9. An automotive emission control module as set forth in claim 1 in which the actuator comprises a movable actuator wall dividing the actuator into two variable volume chamber spaces, and a spring is disposed within one of the two actuator chamber spaces to urge the valve toward closing the main flow passage.
  • 10. An automotive emission control module as set forth in claim 1 in which the actuator comprises an actuator body that mounts on the emission control valve body, and the second pressure sensing passage is internal to both the emission control valve body and the actuator body.
  • 11. An automotive emission control module, comprising:an emission control valve body having an internal main flow passage between a first port and a second port, a valve for selectively restricting flow between the ports, an actuator for operating the valve, a pressure sensor having first and second pressure sensing ports, and first and second pressure sensing passages communicating the first and second pressure sensing ports to the main flow passage for sensing pressure differential along a portion of the length of the flow passage, the second pressure sensing passage extending through the actuator and comprising a chamber space that is disposed between the actuator and the pressure sensor, and a pressure regulating valve including a source pressure port and a regulated pressure port, the pressure regulating valve, in accordance with a regulation signal, modulating source pressure at the source pressure port to a regulated pressure at the regulated pressure port, the first pressure sensing passage communicating the first port to the source pressure port of the pressure regulating valve, and the regulated pressure port of the pressure regulating valve communicating with the actuator.
  • 12. An automotive emission control module as set forth in claim 11 in which the actuator comprises a shaft for operating the valve and two chamber spaces separated by a movable actuator wall that operates the shaft, the regulated pressure port of the pressure regulating valve communicates with one of the two chamber spaces of the actuator, and the other chamber space of the actuator communicates with atmosphere.
  • 13. An automotive emission control module as set forth in claim 12 in which the second pressure sensing passage comprises a chamber space arranged in axial succession with the actuator chamber spaces along an axis of the module, and the chamber space of the second pressure sensing passage is disposed axially beyond the two actuator chamber spaces relative to the valve.
  • 14. An automotive emission control module as set forth in claim 13 in which a separator wall divides the chamber space of the second pressure sensing passage from the one chamber space of the actuator and comprises an annulus having an inner margin sealed to an outside diameter of the shaft and an outer margin sealed to a body of the actuator.
  • 15. An automotive emission control module comprising:an emission control valve body having an internal main flow passage, a valve for selectively restricting the flow passage, an actuator comprising an actuator mechanism for operating the valve, a pressure sensor that provides a signal related to pressure communicated to the pressure sensor, and a pressure sensing passage communicating pressure to the pressure sensor from a location in the main flow passage, the pressure sensing passage including a variable volume chamber space which is external to the actuator mechanism, and the volume of which varies with the operation of the valve by the actuator mechanism.
  • 16. An automotive emission control module as set forth in claim 15 including a movable separator wall that divides the variable volume chamber space from the actuator mechanism.
  • 17. An automotive emission control module as set forth in claim 15 in which the actuator mechanism comprises a tube that operates the valve and that forms a portion of the pressure sensing passage, and the movable wall comprises an annulus having an inner margin sealed to an outside diameter of the tube and an outer margin sealed to the valve body.
  • 18. An automotive emission control module as set forth in claim 15 in which the actuator mechanism comprises two chamber spaces separated by a movable actuator wall that operates the valve, and all three chamber spaces are disposed in axial succession along an axis of the module.
  • 19. An automotive emission control module as set forth in claim 18 in which the variable volume chamber space is disposed axially beyond the two chamber spaces of the actuator mechanism relative to the valve.
  • 20. An automotive emission control module as set forth in claim 19 in which the actuator mechanism comprises a movable actuator wall that divides the two chamber spaces of the actuator mechanism and that operates the valve via a tube which forms a portion of the pressure sensing passage.
  • 21. An automotive emission control module as set forth in claim 20 in which a spring is disposed within one of the chamber spaces of the actuator mechanism and acts on the movable actuator wall to urge the valve head toward seating on a valve seat.
  • 22. An automotive emission control module as set forth in claim 20 in which a movable separator wall divides the variable volume chamber space from one of the two chamber spaces of the actuator mechanism and comprises an annulus having an inner margin sealed to an outside diameter of the tube and an outer margin sealed to a body of the actuator that contains the actuator mechanism.
REFERENCE TO RELATED APPLICATION AND PRIORITY CLAIM

This application expressly claims the benefit of earlier filing date and right of priority from the following patent application: U.S. Provisional Application Ser. No. 60/086,680, filed on May 26, 1998 in the names of John E. Cook and Murray F. Busato and entitled “Integrated Exhaust Gas Recirculation System”. The entirety of that earlier-filed, co-pending patent application is hereby expressly incorporated herein by reference.

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Number Name Date Kind
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4142493 Schira et al. Mar 1979
4173205 Toelle Nov 1979
4195605 Weathers et al. Apr 1980
4231340 Nishimiya et al. Nov 1980
4256076 Bradshaw Mar 1981
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4351285 Bradshaw Sep 1982
4364368 Blanchette Dec 1982
4455987 S{umlaut over (u)}beck et al. Jun 1984
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4497335 Masuda Feb 1985
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4694812 Wendt Sep 1987
5188086 Adkins et al. Feb 1993
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5448981 Cook et al. Sep 1995
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Number Date Country
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Provisional Applications (1)
Number Date Country
60/086680 May 1998 US