The present invention relates to valve trains for internal combustion engines. More particularly, the present invention relates to an improved valve deactivation device for use in a valve train for internal combustion engines.
Modern multi-cylinder internal combustion engines include a valve train having intake and exhaust valves disposed in the cylinder head above each combustion cylinder. The intake and exhaust valves connect intake and exhaust ports with each combustion cylinder. The intake and exhaust valves are generally poppet-type valves having a generally mushroom-shaped head and a elongated cylindrical stem extending from the valve head. A spring biases the valve head in a fully closed position against a valve seat in the cylinder head. Historically, engine valves were actuated from the fully closed position to a fully open position by a underhead camshaft, pushrod, and rocker arm assembly. Hydraulic lifters, which utilize pressurized hydraulic fluid to actuate a piston to reciprocate the valve, were added between the motion of the rocker arm and the valve stem as a means for adjusting valve lash. In later developments, overhead camshafts eliminated the pushrod and, occasionally, the rocker arm for a more direct actuation of the valves.
Reduction of fuel consumption and improved emissions, especially for passenger cars, have been important considerations for internal combustion engine design. One engine design change for reducing fuel consumption and improving emissions has been a shutdown of individual cylinders during engine operation, especially during partial load. A cylinder shutdown increases intake manifold pressure thereby allowing the remaining cylinders to operate at increased average pressure and thus have a reduced specific consumption. For cylinder shutdown, it is not only necessary to provide for an interruption of the fuel supply, it is furthermore expedient to interrupt the load flow through the respective cylinder by shutting down one or more valves, especially the intake valve of the respective cylinder.
Valve deactivation devices have been employed to shut down valves in an operating engine. When valves are deactivated, friction losses in the valve train are reduced. Many prior art valve deactivation devices undesirably include numerous components that make the devices costly to produce and assemble. Still other prior art devices operate by decoupling components of rocker arms that may not necessarily realign properly in order to recouple and reactivate the rocker arm. Other valve deactivation devices, because of their configuration, are not capable of providing the needed structure to provide suitable tolerances in mating of parts to provide proper function and avoid objectionable noisy operation and unacceptable wear in modern high efficient engines. For example, the valve activator of the cam mechanism for internal combustion engines described in the Lotus Cars Limited UK Patent Application GB2,333,322A, published Jul. 21, 1999, lacks the necessary prerequisites of providing measured, selectively sorted and mated (and not interchangeable) specifications to provide necessary clearances for the desired engine performance efficiency.
The present invention provides a needed improvement in valve deactivation mechanisms involving the mating of non-interchangeable sections that are maintained as a set and comprises a valve deactivation device that permits a rocker arm assembly to deactivate using fewer moving parts than prior art assemblies.
The present invention is directed to an improved rocker arm assembly having a valve deactivation device for a valve train. As distinguished from the prior art cam mechanism disclosed in the above referenced UK Patent Application GB 2,333,322A, the cam follower and the valve actuator sections of the rocker arm are independently mounted on the rocker shaft each for free rotation about the rocker shaft. The present invention comprises an arrangement in which the cam follower and valve actuator sections of the rocker arm are not independently mounted on the rocker shaft. In particular the invention comprises three forms, each creating a rocker arm assembly which is in turn mounted on, but not independent of, the rocker shaft for free rotation about it.
In the first form, the valve actuator section and cam follower section are mounted on a tube and secured thereon to create a rocker arm assembly. In the second form, the valve actuator section comprises a tube element onto which the cam follower section is mounted and secured thereon to create a rocker arm assembly. In the third form, the cam follower section comprises a tube element onto which the valve actuator section is mounted and secured thereon to create a rocker arm assembly.
According to the invention, it is necessary that a close control of the lateral clearance between the rocker arm sections and mechanical lash within the valve deactivating device be maintained. The control and mating of the lateral clearance between the rocker arm sections is a prerequisite to ensure adequate engagement of the locking pin within the two rocker arm sections in order to provide adequate locking mechanism durability and overall rocker arm assembly mechanical stiffness.
Referring to the prior art cam mechanism disclosed in the above referenced UK Patent Application GB2,333,322A, the force produced by the springs biasing the locking pins to their normally extended position produces a reaction force which in turn separates the cam follower sections from the valve actuator section. As stated in the above referenced UK Patent Application GB 2,333,322A, while mounted on the rocker shaft, the rocker arm sections are independent of the rocker shaft and free, not only to rotate about it, but also to slide along it. Increasing the lateral clearance between the sections results in a decrease to the engaged length of the locking pins within each section. The above referenced UK Patent Application GB2,333,322A lacks a disclosure of any means to limit the lateral clearance of the rocker arm assembly; this clearance varies considerably due to manufacturing variation of the rocker arm sections and of the cylinder head into which the rocker arm assembly is installed. The present invention overcomes this difficulty by measuring and select-fitting, by shimming, or otherwise adjusting the rocker arm sections to obtain the proper limited lateral clearance i.e. within a variational tolerance, and then by means of the structures described, maintains the rocker arm as a complete (dedicated) assembly which requires no further adjustment of lateral clearance upon installation into an engine.
The control of mechanical lash, the clearance between the lock pin in one section and that of the surface receiving the lock pin in the other section of the rocker arm, is a pre-requisite to providing smooth functioning avoiding objectionable noisy operation and preventing excessive wear. Referring to the prior art cam mechanism disclosed in the above referenced UK Patent Application GB 2,333,322A, a stop is provided on one of the valve actuator and cam follower sections of the rocker arm to define a limit position in which the locking pins align with their mating bores. However, this reference provides no disclosure of any means to limit the mechanical lash or clearance between the locking pins of either cam follower section and of their mating surfaces in the valve actuator section. This clearance can be and often is found to prove considerable and thus excessive due to manufacturing variation of the rocker arm sections, especially with respect to the location of the locking pin bores, piston bores, rocker shaft bores, and the diameter of the locking pins. In addition, because the cam mechanism described in UK Patent Application GB 2,333,322A comprises two separate locking pins, if the mechanical lash at each locking pin is not identical, only one locking pin will engage the mating surface of the locking mechanism with the result that only one of the two locking pins transfers the entire load from the cam follower section to the valve actuator section. This increases the Hertzian contact stress at the locking pin mating surfaces, substantially decreasing the load carrying capacity and durability of the rocker arm assembly.
The present invention overcomes these drawbacks by measuring and select-fitting, shimming, or otherwise adjusting the rocker arm sections to obtain the proper mechanical lash and then by means of the structures described, maintains the integrity of the rocker arm as a complete assembly which requires no further adjustment of mechanical lash upon installation into an engine. As such, the components of the integrated assembly of a finished rocker arm are dedicated, i.e. are not interchangeable with others and must be maintained as a set. The improvements set forth in the present invention precludes the inadvertent interchange of components as is permitted by the prior art cam mechanism disclosed in the above referenced UK Patent Application GB 2,333,322A.
The rocker arm assembly of the valve train may be switchable between an activated condition and a deactivated condition. In one embodiment, the rocker arm assembly includes a valve actuator section, a cam follower section that is rotatably coupled to the valve actuator section, and a valve deactivation device. The valve deactivation device is coupled to the cam follower section. The valve deactivation device includes a lock pin that selectively cooperates with a surface of the valve actuator section to switch the rocker arm assembly to the activated condition. The lock pin is moveable between a deactivated position and a activated position; the activated position corresponding to the valve activated condition, and the deactivated position corresponding to the valve deactivated condition. In another embodiment of the invention, a rocker arm assembly includes a valve actuator section, a cam follower section, and a valve deactivation device. The cam follower section is rotatably coupled to the valve actuator section. The valve actuator section and the cam follower section are rotatable generally about a common axis. The common axis is defined by a rocker shaft. At least a portion of the valve actuator section and at least a portion of the cam follower section are concentrically positioned about the common axis. The valve deactivation device is coupled to the rocker arm assembly to switch the rocker arm assembly between the valve activated condition and a valve deactivated condition. In a further embodiment, a valve deactivation device for a rocker arm assembly includes a hydraulically operated lock pin coupled to the rocker arm assembly and a return spring biasing the lock pin in the activated position. The lock pin selectively engages a surface of the rocker arm assembly to switch the rocker arm assembly to the valve activated condition. The lock pin is movable between a deactivated position and an activated position, the activated position corresponding to the valve activated condition, and the deactivated position corresponding to a valve deactivated condition.
a and 5b are sectional views taken along line 5-5 of
In the mechanism of the invention, the cam follower and valve actuator sections of the rocker arm are not independent of the rocker shaft and as noted above comprise three forms, each creating a rocker arm assembly which is in turn mounted on the rocker shaft for free rotation about it.
In the first form, the rocker arm assembly comprises the valve actuator section and cam follower section are mounted on and secured to a tube. In the second form, the valve actuator for the rocker arm assembly is created by a tube element onto which the cam follower section is mounted and secured thereon. In the third form, the cam follower section for the rocker arm assembly comprises a tube element onto which the valve actuator section is mounted and secured thereon.
It is necessary to create a rocker arm providing control of both (a) the lateral clearance between the two rocker arm sections, and (b) the clearance or mechanical lash between the locking pin in one section and the locking pin receiving hole in the other section. As such, the relative free rotation of one section to the other is strictly limited at those times when the locking pin selectively engages its receiving hole, joining the two sections in order to actuate the companion engine valve.
Due to manufacturing variation and because the two clearances identified above must be sufficiently small to ensure proper function to avoid objectionably noisy operation, discrete valve actuator sections and cam follower sections must be measured, sorted, and selected and mated or be shimmed or otherwise adjusted by appropriate means to provide the necessary close tolerance clearances, typically 50-150 μm. As such, the components of a finished rocker arm assembly are dedicated and are not interchangeable with others and must be maintained as a set. The improvements set forth in this invention prevent the inadvertent interchange of components as is permitted by the prior art cam mechanism such as that disclosed in UK Patent Application GB 2,333,322A.
In the alternative second and third embodiment of the invention, the assembly comprises a tube element section onto which the other section is mounted and wherein the tube element is fixedly attached to a rocker arm section, for example by an interference press fit or metallurgical or adhesive bonding.
With reference to
Referring to
With specific reference to
Referring again to
As shown in
Lock pin 92 is illustrated in
As best seen in
Referring again to
Referring again to
To deactivate rocker arm assembly 30 from the activated condition, pressurized oil is introduced into hydraulic cavity 160, thereby urging lock pin 92 toward cap 96, against the biasing force of return spring 94. The existence of clearance or mechanical lash 164 (
To activate rocker arm assembly 30 from the deactivated condition, pressurized oil is released from hydraulic cavity 160, thereby allowing return spring 94 to urge lock pin 92 toward valve arm 34. The existence of clearance or mechanical lash 164 (
Preferably, the flow of oil into hydraulic cavity 160 is controlled by an electronic solenoid valve (not shown), although other conventional means may be utilized. Also preferably, the oil flows through the solenoid valve then through a channel (not shown) in the cylinder head on into the rocker shaft 22 and continues through the valve arm 34 into the cam arm 32 through oil inlet channel past oil port 152 and into the hydraulic cavity 160. While the deactivation portion 54 has been described herein as attached to valve arm 34, it will be appreciated that the deactivation device may be attached to cam arm 32 or other portions of valve train assembly 20 to accomplish the same purpose. While many components of valve train assembly are described as tubular or cylindrical, it is understood that at least some of these components and their complementary shaped components can be formed as a rod or in shapes other than circular to perform a similar function.
It is to be understood that the above description is intended to be illustrative and not limiting. Many embodiments will be apparent to those of skill in the art upon reading the above description. Therefore, the scope of the invention should be determined not with reference to the above description, but instead with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.
This application is a Continuation-in-Part of U.S. application Ser. No. 11/060,663 filed on Feb. 17, 2005; which claims the benefit of U.S. Provisional Application Ser. No. 60/545,739, filed on Feb. 18, 2004, and U.S. Provisional Application Ser. No. 60/546,692, filed on Feb. 20, 2004, the contents of which are incorporated in their entireties by reference.
Number | Date | Country | |
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60545739 | Feb 2004 | US | |
60546692 | Feb 2004 | US |
Number | Date | Country | |
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Parent | 11060663 | Feb 2005 | US |
Child | 11675686 | Feb 2007 | US |