The present teachings relate to valvetrains, particularly valvetrains providing variable valve lift (VVL) or cylinder deactivation (CDA).
Hydraulically actuated latches are used on some rocker arm assemblies to implement variable valve lift (VVL) or cylinder deactivation (CDA). For example, some switching roller finger followers (SRFF) use hydraulically actuated latches. In these systems, pressurized oil from an oil pump may be used for latch actuation. The flow of pressurized oil may be regulated by an oil control valve (OCV) under the supervision of an engine control unit (ECU). A separate feed from the same source provides oil for hydraulic lash adjustment. In these systems, each rocker arm assembly has two hydraulic feeds, which entails a degree of complexity and equipment cost.
The oil demands of these hydraulic feeds may approach the limits of existing supply systems. The complexity and demands for oil in some valvetrain systems can be reduced by replacing hydraulically latched rocker arm assemblies with electrically latched rocker arm assemblies. Electrically latched rocker arm assemblies require power. There is an ongoing need for reliable structures for power transfer to the rocker arm assembly.
The present teachings provide a valvetrain suitable for an internal combustion engine that includes a combustion chamber, a movable valve having a seat formed within the combustion chamber, and a camshaft. The valvetrain includes a camshaft and a rocker arm assembly. The rocker arm assembly includes a rocker arm, a cam follower configured to engage a cam mounted on the camshaft as the camshaft rotates, and an electrical device mounted to the rocker arm. The rocker arm assembly may rest on a pivot that is supported by a cylinder head of the engine. The electrical device may be an electromagnet of an electromagnetic latch assembly. The present teachings relate to powering the electrical device. If the electrical device were powered with conventional wiring, it would be possible for a wire would be caught, clipped, or fatigued and consequently short out.
According to some aspects of the present teachings, an electrical circuit that powers the electrical device includes a connection formed by abutment between a first part and a second part, which are two distinct parts. The rocker arm assembly is operative to move the second part relative to the first part in response to actuation of the rocker arm assembly through the cam follower. The relative movement causes the second part to slide over a surface of the first part. The first part is a contact pad having resiliency that biases the contact pad against the second part. Structuring the second part as a resilient contact pad allows for a compact structure in which the electrical connection may be maintained even as the rocker arm assembly undergoes a wide range of motion relative to the second part. A contact pad mounted to a part distinct from the rocker arm assembly may be larger than a contact pad mounted on the rocker arm. In some of these teachings, the contact pad is a leaf spring.
In some of these teachings, the contact pad is held by a mounting frame that rests against the cylinder head of the engine. In some of these teachings the mounting frame abuts a pivot that provides a fulcrum for the rocker arm assembly. In some of these teachings that the mounting frame goes around the pivot. In some of these teaching, the mounting frame abuts two or more pivots that provide fulcrums for rocker arm assemblies of the valvetrain. In some of these teachings, the mounting frame goes around two of the pivots. In some of these teachings, the mounting frame is over-molded about the contact pad. In some of these teachings, the contact pad is coupled to a metal lead. In some of these teachings the mounting frame supports the metal lead. In some of these teachings the mounting frame contains the metal lead. The mounting frames of the present disclosure provide structures that hold the contact pads reliably and with correct positioning while making efficient use of the limited space around the rocker arm assemblies.
In some of these teachings, the second part is held to the rocker arm. In some of these teachings, the second part is a contact pin. In some of these teachings, the second part is held to one side of the rocker arm. In some of these teaching the electrical circuit includes a second electrical connection made by abutment between surfaces of two distinct parts, the second connection being made between a second resilient contact pad and second a contact pin held to the opposite side of the rocker arm from the first resilient contact pad and the first contact pin.
According to some aspects of the present teachings, the contact pads bend toward the rocker arm assembly in an area above the contact pins. The inward bends are operative together with the contact pins to improve retention of the rocker arm assembly on a pivot. The inward bends may be provided by protrusions in the contact pads. The contact pads may be sheet metal. The protrusions may be bulges on the contact pad surfaces, such as bulges formed by inward facing rolls in sheet metal. In some of these teaching, the protrusions or inward bends are formed by rolls in the contact pads that form inward-facing lips.
In some of these teachings, the valvetrain includes a latch assembly mounted on the rocker arm assembly and the latch assembly includes a latch pin and an electromagnet that is powered through two electrical connections according to the present teachings. The electromagnet is operable to move the latch pin between a first latch pin position and a second latch pin position. A power transfer module includes a mounting frame that supports the two contact pads of the two electrical connections. The mounting frame has a base that abuts a pivot that provides a fulcrum for the rocker arm assembly. The contact pads extend upward from the base and terminate at a height that is below a height the which the rocker arm assembly rises above the pivot. In some of these teachings, the contact pads extend upwards 20 mm or less. In some of these teachings, the contact pads are free-floating above the base. The short contact pads that extend upward from the base provide a better package design than longer contact pads or contact pads that are held at the top as well as at the bottom. The design allows a rocker arm assembly to be installed by lowering it onto a pivot after the mounting frame has been placed on the cylinder head. The mounting frame may fit around the pivot and be held in position by the pivot.
In some of these teachings, the contact pads angle outward from the rocker arm assembly as they extend upward from the base. Having the contact pads angle outward minimizing the possibility of the rocker arm assembly rocking to one or the other side to strike one of the contact pads. Consistent with this alternative, the contact pads may bend inward above the contact pins. In a method according to the present teachings, a rocker arm assembly is installed on a pivot by deforming the contact pads outward to get the contact pins past the inward bends.
The rocker arm assembly has a front end and a back end. The front end is the end proximate to which the rocker arm assembly abuts a valve stem. The back end is proximate the location where the rocker arm assembly rests on the pivot. The pivot may have a dome-shaped upper surface and the rocker arm may have a gothic profile formed in its bottom surface to interface with the dome of the pivot. In some of these teachings, the contact pads extend toward the back end as they extend upward from the base. In some of these teachings, the inward bends in the contact pads above the contact pins continue into the backward extended area of the contact pad. This design facilitates retention of the rocker arm assembly on the pivot during a critical shift wherein the rocker arm may jump on the pivot and be displaced toward the back end. A contact pad that extends backward as it rises from the base to provide this backward area for contact pin-retention is more easily packaged as compared to the alternative of providing a contact pad that extends sufficiently far backward from the base on upward.
In some of these teachings the contact pins on the rocker arm are held by a contact frame that extends over the back of the rocker arm and around the sides of the rocker arm to where the contact pins are. In some of these teachings, the contact frame fits partially within an opening formed in the back of the rocker arm. In some of these teachings, conductors of the electrical circuit running from the contact pins at the sides of the rocker arm are enclosed within the contact frame. In some of these teachings, the contact frame snaps around the sides of the rocker arm. In some of these teachings, the contact frame must be deformed to be placed in or removed from its position on the rocker arm. In some of these teachings, a combination of protrusions and indentations on the contact frame and the rocker arm necessitate the deformation. In some of these teachings, the contact pins are piloted into the sides of the rocker arm for stability. The contact frame is a compact structure for holding the electrical connections and their wiring. It is particularly well suited for adapting latching rocker arm assemblies that were designed for hydraulic actuation for use with electrical actuation. Having contact pins on both sides of the rocker arm balances the forces placed by the resilient contact pads on the rocker arm assembly.
In some of these teachings, the rocker arm assembly is configured to pivot approximately on an axis when actuated through the cam follower and the electrical connection is made proximate the axis. In some of these teachings, pivoting induces movements of the rocker arm assembly at the location of the electrical connection that are 10% or less the simultaneous movements of the rocker arm assembly at points on the rocker arm assembly distal from the axis.
In some of these teachings, the abutting surfaces of the first part and the second part are electrically isolated from ground. In some of these teachings, the ground corresponds to a cylinder head of an engine in which the valvetrain is installed. In some of these teachings, the electrical connection couples the electrical device with a power source. In some of these teachings, the electrical device is an electromagnetic latch assembly. In some of these teachings, the electromagnetic latch assembly switches the rocker arm assembly between first and second configurations. In the first configuration, the rocker arm assembly is operative to actuate a movable valve in response to rotation of a camshaft to produce a first valve lift profile. In the second configuration, the rocker arm assembly is operative to actuate the movable valve in response to rotation of the camshaft to produce a second valve lift profile, which is distinct from the first valve lift profile, or the movable valve is deactivated. In some of these teachings, a processor is operatively coupled to communicate with the electrical device through the electrical connection.
In some of these teachings, the valvetrain is operable to move the rocker arm assembly in a way that causes the contact area of the electrical connection to move between first and second portions of the resilient contact pad and the electrical circuit resistance varies according to which of the first and second portions of the contact pad the connection is made through. In some of these teachings, the second portion of the resilient contact pad has a coating that increases the resistance. These structures may be used to provide on board diagnostic feedback.
Some aspects of the present teachings relate to an internal combustion engine in which a valvetrain according to the present teachings is installed. The internal combustion engine includes a cylinder head. In some of these teachings, the electrical connection is electrically isolated from the cylinder head. In some of these teachings, a mounting frame that holds the resilient contact pad rests on the cylinder head. In some of these teachings, the mounting frame rests on the cylinder head adjacent a pivot for the rocker arm assembly. In some of these teachings, the mounting frame also rests on the cylinder head at a point above the rocker arm assembly.
The primary purpose of this summary has been to present certain of the inventors' concepts in a simplified form to facilitate understanding of the more detailed description that follows. This summary is not a comprehensive description of every one of the inventors' concepts or every combination of the inventors' concepts that can be considered “invention”. Other concepts of the inventors will be conveyed to one of ordinary skill in the art by the following detailed description together with the drawings. The specifics disclosed herein may be generalized, narrowed, and combined in various ways with the ultimate statement of what the inventors claim as their invention being reserved for the claims that follow.
Rocker arm assemblies 203 each include two pivotally connected rocker arms, rocker arm 401 and rocker arm 108. Rocker arm 401 and rocker arm 108 are selectively engaged by a latch pin (not shown) of an electromagnetic latch assembly 122 that is mounted to rocker arm 401. Electromagnetic latch assembly 122 includes a coil (not shown). Energizing the coil with DC current in a forward direction actuates the latch pin to an engaging position. Energizing the coil with DC current in a reverse direction actuates the latch pin to a non-engaging position. The coil receives power via contact pins 403, which are mounted to and held at the sides of rocker arm 401. Contact pins 403 may be positioned within pilot holes formed in the sides of rocker arm 401. Regardless, insulation may be provided to prevent electrical contact between contact pins 403 and rocker arm 401.
Power transfer module 223 includes leaf springs 215. Leaf springs 215 are electrical conductors. Power transfer module 223 is designed to hold leaf springs 215 in abutment with contact pins 403. Electrical connections through which electromagnetic latch assembly 122 may be powered are made between contact pins 403 and leaf springs 215. Electrical contact may be maintained even as contact pins 403 slide over the surfaces of leaf springs 215 in connection with actuation of rocker arm assemblies 203 by camshaft 501 through cams 503 or in connection with lash adjustment by extension and contraction of pivots 303.
Rocker arm assemblies 203 are configured to undergo a pivoting motion as they are actuated by cams 503. This pivoting occurs approximately on an axis. In some of these teachings, contact pins 403 are located proximate that axis to keep the relative motions between contact pins 403 and leaf springs 215 small. The range of motion cams 503 induce on contact pins 403 may be 10% or less the range of motion cams 503 induce on parts of rocker arm assemblies 203 most distant from the axis. In some of these teachings, the range of motion for contact pins 403 is 2% or less the motion induced on the parts of rocker arm assemblies 203 most distant from the axis.
On the other hand, in some of these teachings, a certain range of motion between contact pins 403 and leaf springs 215 is desirable. A portion of the surface of a leaf spring 215 may be coated with a material that significantly increase the resistance of an electrical circuit comprising a connection between contact pin 403 and leaf spring 215. The material may be, for example, diamond-like carbon. Contact pin 403 may move to that high resistance surface only when cam 503 is lifting rocker arm 401. The increase in resistance may be detected and used to provide rocker arm position information, which in turn may be used in diagnostic or control operations.
As can be seen in
Contact plug 219 may be used to couple power transfer module 224 to a vehicle's electrical system. An elevated location, such as a location above the height of rocker arm assembly 203, facilitates the coupling with the vehicle's electrical system in that wires connecting to contacts 219 have a short distance to travel before passing through the valve cover (not shown). The wires may pass through the valve cover adjacent a spark plug tower. One option is to run the wires into and out of a spark plug tower in order that they pass through the valve cover within a spark plug tower.
Power transfer module 224 has a lower portion 241 that rests against cylinder head 201 adjacent pivot 303 and an upper portion 243 that fits over and may rest on a raised portion 245 of cylinder head 201. Raised portion 245 may be above rocker arm assembly 203. “Above” is used in the sense that rocker arm assembly 203 is “above” a combustion chamber contained within cylinder head 201. Pivots 303 fits through openings 225 in power transfer module 224. Openings 225 abut pivots 303 and help locate power transfer module 224. Openings 225 may fit tightly around pivots 303, whereby pivots 303 may by joined to power transfer module 224 prior to installation.
Openings 233 may be formed in lower portion 241 of power transfer module 224 and used to bolt power transfer module 224 to cylinder head 201. Alternatively, or in addition, openings may be formed in upper portion 243 of power transfer module 224 and used to bolt power transfer module 224 to raised portion 245 of cylinder head 201.
Rocker arm assembly 203 may be less than 25 mm in width and is preferably less than 22 mm in width. As shown in
Electromagnetic latch assembly 122 may be installed in rocker arm 401 through an opening 116 (see
Rocker arm assemblies 203 may be installed on pivots 303 by pushing them downward until gothics 409 of rocker arms 401 contact domes 407 of pivots 303. This installation process may include deforming contact pads 105 outward to allow contact pins 403 to move past inward facing rolls 111. After installation, contact pads 105 are resiliently biased against contact pins 403. If rocker arm assembly 203 begins to rise off pivot 303, contact pins 403 may encounter inward facing rolls 111, which may then function to retain rocker arm assembly 203 on pivot 303.
The components and features of the present disclosure have been shown and/or described in terms of certain embodiments and examples. While a particular component or feature, or a broad or narrow formulation of that component or feature, may have been described in relation to only one embodiment or one example, all components and features in either their broad or narrow formulations may be combined with other components or features to the extent such combinations would be recognized as logical by one of ordinary skill in the art.
Number | Name | Date | Kind |
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5544626 | Diggs | Aug 1996 | A |
10358951 | Liskar et al. | Jul 2019 | B2 |
20030111031 | Hendricksma | Jun 2003 | A1 |
20150167772 | Street | Jun 2015 | A1 |
20180142583 | Liskar | May 2018 | A1 |
20180195419 | Liskar | Jul 2018 | A1 |
20190257227 | Mccarthy, Jr. | Aug 2019 | A1 |
Number | Date | Country |
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0833041 | Feb 2002 | EP |
WO-2016028812 | Feb 2016 | WO |
WO-2018075392 | Apr 2018 | WO |
Number | Date | Country | |
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20200095908 A1 | Mar 2020 | US |
Number | Date | Country | |
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62503303 | May 2017 | US | |
62849447 | May 2019 | US |
Number | Date | Country | |
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Parent | PCT/US2018/031697 | May 2018 | US |
Child | 16677730 | US |