JP7336405B2 - Exhaust valve and its manufacturing method - Google Patents

Description

The present invention relates to an exhaust valve that is installed in an exhaust passage of an automobile or the like through which exhaust gas flows, and that adjusts the flow rate of exhaust gas and the exhaust sound by opening and closing operations, and a manufacturing method thereof.

2. Description of the Related Art Conventionally, there is an exhaust valve disclosed in Patent Document 1 as an exhaust valve that is installed in an exhaust passage of an automobile or the like through which exhaust gas flows and adjusts the flow rate of exhaust gas by opening and closing operations. In the exhaust valve of Patent Document 1, a pipe connecting an upstream pipe and a downstream pipe of the exhaust is installed, and a shutter that rotates according to the rotation of the rotary shaft driven by the actuator is arranged in the pipe, and is located downstream of the pipe. A substantially arc-shaped first stopper and an upstream substantially arc-shaped second stopper are attached by welding to the inner surface, respectively, and the substantially arc-shaped first stopper and the substantially arc-shaped second stopper are installed at a position where the rotating shutter closes the exhaust path. It abuts against a stopper.

In addition, as an exhaust valve with a different structure, a thick pipe body is used for the pipe body that connects the upstream pipe and the downstream pipe of the exhaust, and the parts corresponding to the above-mentioned first stopper and second stopper are the pipe body It is also known that the inner side is cut so that the rotating shutter abuts on the first and second cut-formed stoppers at the position for closing the exhaust passage.

U.S. Pat. No. 10167785

By the way, in the exhaust valve of Patent Document 1, when the first stopper and the second stopper, which are separate members, are welded to the tubular body and manufactured, the first stopper and the tubular body are welded together in order to ensure the positional accuracy. A positioning and fitting mechanism that positions and holds the first stopper and the tubular body for fitting, and a positioning and fitting mechanism that positions and holds the second stopper and the tubular body when the second stopper and the tubular body are welded together. A positioning fitting mechanism and two positioning welding processes are required. Therefore, the manufacturing efficiency is inferior and the manufacturing cost is high.

Furthermore, in the exhaust valve of Patent Document 1, a clearance for inserting and positioning the first stopper in the tubular body and a clearance for inserting and positioning the second stopper in the tubular body are set, respectively. Since it is necessary to assemble the first stopper to the tube body and to assemble the second stopper to the tubular body, there are many gaps for fitting and positioning. If the clearance for fitting and positioning increases, the fitting accuracy between the first stopper, the second stopper, and the tubular body is lowered, and the product accuracy after assembly is lowered.

Further, in the case of the exhaust valve having a different structure in which the portions corresponding to the first stopper and the second stopper are formed by cutting, the manufacturing cost is increased because cutting is required. Furthermore, it is necessary to use a thick tubular body in order to secure a cutting margin for cutting, which increases the weight of the exhaust valve. This increase in weight of the exhaust valve reduces the fuel consumption performance when the exhaust valve is installed in the exhaust passage of the automobile.

SUMMARY OF THE INVENTION The present invention is proposed in view of the above problems, and an object thereof is to provide an exhaust valve that is lightweight, can improve manufacturing efficiency, reduce manufacturing costs, and improve product precision, and a manufacturing method thereof.

The exhaust valve of the present invention is mounted on a tubular body that connects an exhaust upstream pipe and a downstream pipe, and a rotating shaft that rotates when driven by an actuator, and is arranged in the tubular body to open and close an exhaust flow path in the tubular body. a rotatable valve plate, and a stopper fixed in the tubular body, the stopper comprising a base portion having an insertion hole into which the rotating shaft is inserted, and one side of the exhaust upstream and downstream sides of the base portion. a first contact portion extending along the inner peripheral surface of the tubular body; It is a substantially C-shaped integrally formed member having a second contact portion extending to the side, and the first contact portion and the second contact portion are formed at a position where the valve plate closes the exhaust flow path. It abuts on the abutment portion.
According to this, by making the stopper an integrally formed member, the number of parts can be reduced, and the number of positioning and fitting mechanisms for the stopper and the tubular body and the number of positioning and fixing processes can be reduced, thereby improving manufacturing efficiency. It is possible to reduce manufacturing costs. In addition, since it is only necessary to fit and assemble the stopper of one integrally formed member and the tubular body, it is possible to reduce the gap for fitting and positioning. It can increase the accuracy and improve the product quality of the exhaust valve.

In the exhaust valve of the present invention, the valve plate is formed in a stepped plate shape in which a substantially semicircular first flat plate portion and a substantially semicircular second flat plate portion are integrally connected via a curved plate portion, The first contact portion and the second contact portion of the substantially C-shaped stopper are formed in a substantially arc shape, respectively. is set larger than the diameter of the rotating shaft.
According to this, it is possible to prevent interference and contact between the first contact portion, the second contact portion, and the rotating shaft of the valve plate at the position facing the base portion of the stopper in the tubular body. Attachment work can also be facilitated. In addition, it is possible to extend one or both of the substantially arc-shaped first contact portion and the substantially arc-shaped second contact portion to a position overlapping the rotation shaft in the axial direction of the tubular body. It is possible to increase the contact distance and area between the contact surface of the first contact portion and the contact surface of the second contact portion, or the contact surface of the second contact portion. can be suppressed as much as possible. In addition, while the product accuracy can be improved by aligning the rotation shaft insertion hole of the tubular body with the insertion hole of the rotation shaft of the base, the substantially arc-shaped first contact portion at the position facing the base of the stopper in the tubular body By arranging the second abutment portions apart from each other, it is possible to widen the allowable range of dimensional accuracy and improve the yield.

A method of manufacturing an exhaust valve of the present invention is a method of manufacturing an exhaust valve of the present invention, comprising: a base having an insertion hole into which a rotating shaft is inserted; and a first contact portion extending along the inner peripheral surface of the base portion and extending along the inner peripheral surface of the tubular body on the other upstream and downstream side of the base and on the opposite side to the first contact portion The insertion hole of the base of the stopper , which is substantially C-shaped in front view and configured by integrally forming the second contact portion, and the rotation shaft formed in the peripheral wall of the pipe connecting the upstream pipe and the downstream pipe of the exhaust are inserted. A step of fitting the stopper into the tubular body by aligning the positions of the holes is provided.
According to this, the position of the hole for inserting the rotating shaft in the base of the stopper and the hole for inserting the rotating shaft formed in the peripheral wall of the tubular body can be aligned, and the exhaust valve can be assembled on the basis of this position, thereby facilitating the manufacturing work. be able to. In addition, it is possible to easily ensure the required degree of coaxiality between the insertion hole for the rotation shaft of the stopper, the insertion hole for the rotation shaft of the tubular body peripheral wall, and the rotation shaft. Product quality can be improved. In addition, since it is possible to ensure the required coaxiality between the insertion hole for the rotation shaft of the stopper, the rotation shaft insertion hole in the peripheral wall of the tube, and the rotation shaft, friction during the rotation of the rotation shaft and the valve plate can be reduced. In addition, the contact surface of the first contact portion and the contact surface of the second contact portion reliably contact the valve plate with the set contact distance and contact area. As a result, leakage of exhaust gas when the valve plate is closed can be suppressed as much as possible.

The exhaust valve of the present invention is lightweight, and can improve manufacturing efficiency, reduce manufacturing costs, and improve product accuracy.

FIG. 4 is a perspective explanatory view of a closed state of the exhaust valve of the embodiment according to the present invention; FIG. 4 is a transverse explanatory diagram of an open state of the exhaust valve of the embodiment; FIG. 4 is a longitudinal explanatory view of the open state of the exhaust valve of the embodiment as viewed from the bottom side. FIG. 4 is a longitudinal explanatory view of the closed state of the exhaust valve of the embodiment as viewed from the bottom side; FIG. 4 is a partial cross-sectional explanatory view for explaining a closed state of the exhaust valve of the embodiment; (a) is a perspective view of a stopper in the exhaust valve of the embodiment, (b) is its plan view, (c) is its side view, and (d) is its bottom view.

[Exhaust valve of the embodiment]
An exhaust valve 1 according to an embodiment of the present invention is installed in an exhaust passage of an automobile through which exhaust gas flows, and adjusts the flow rate of exhaust gas and the exhaust sound by opening and closing the valve. As shown in FIGS. 1 to 5, the exhaust valve 1 is arranged in a substantially cylindrical tubular body 2 and in a direction perpendicular to the axial direction of the tubular body 2 so as to pass through substantially the center of the tubular body 2. A rotating shaft 3 penetrating through the peripheral wall 21 , a valve plate 4 fixedly attached to the rotating shaft 3 and arranged inside the tubular body 2 , and a stopper 5 fixed inside the tubular body 2 are provided.

The pipe body 2 connects an exhaust upstream pipe 11 and a downstream pipe 12 that constitute an exhaust passage. Downstream pipe 12 is fixed. The method of fixing the upstream pipe 11 and the downstream pipe 12 for exhaust gas to the tubular body 2 is appropriate. It is fixed by butt welding, or the upstream pipe 11 is fitted to one end side of the tubular body 2 in the pipe axial direction, and the downstream pipe 12 is fitted to the other end side, and fixed by fillet welding or penetration welding. Alternatively, the upstream pipe 11 and the downstream pipe 12 are fitted to one end side of the pipe body 2 in the pipe axial direction and the downstream pipe 12 are fitted to the other end side of the pipe body 2, and fixed by fillet welding or penetration welding. is possible.

Rotating shaft insertion holes 22 and 23 are formed in the peripheral wall 21 of the tubular body 2 at positions facing each other in the radial direction. It is arranged so that the end is inserted into the rotary shaft insertion hole 23 . A substantially hat-shaped bearing case 61 with an open top is provided outside the rotating shaft insertion hole 22 , and a flange 611 deformed into a shape following the outer peripheral surface of the peripheral wall 21 of the tubular body 2 is attached to the outer peripheral surface of the peripheral wall 21 . It is arranged so as to follow and is fixed by welding or the like. A bearing 71 is accommodated in the bearing case 61 and supports one axial end of the rotating shaft 3 protruding from the rotating shaft insertion hole 22 to the outside of the tubular body 2 .

A substantially hat-shaped bearing case 62 is provided outside the rotary shaft insertion hole 23 , and a collar portion 621 deformed to follow the outer peripheral surface of the peripheral wall 21 of the tubular body 2 is arranged along the outer peripheral surface of the peripheral wall 21 . and fixed by welding or the like. A bearing 72 is accommodated in the bearing case 62 , and supports the other end in the axial direction of the rotating shaft 3 projecting from the rotating shaft insertion hole 23 to the outside of the tubular body 2 .

One axial end of the rotating shaft 3 protrudes outside the bearing 71 and is connected to the drive transmission portion 81 of the actuator 8 . The rotary shaft 3 is driven by the actuator 8 to rotate via a drive transmission portion 81 , and according to the rotation of the rotary shaft 3 , the valve plate opens and closes the exhaust flow path in the tubular body 2 . 4 rotates.

In the illustrated example, the valve plate 4 is formed in a substantially circular shape when viewed from the front. It has a stepped plate shape. The substantially semicircular first flat plate portion 41 and the substantially semicircular second flat plate portion 42 are arranged to extend substantially parallel to each other, and the first flat plate portion 41 is closer to the axis of the rotation shaft 3 than the second flat plate portion 42 is. It is formed long in a direction orthogonal to the direction and has a large area. A curved plate portion 43 provided between the first flat plate portion 41 and the second flat plate portion 42 is arranged substantially along the outer peripheral surface of the rotating shaft 3 and fixed to the rotating shaft 3 by welding or the like.

As shown in FIGS. 2 to 6, the stopper 5 is a substantially C-shaped integrally formed member having a base portion 51 formed with an insertion hole 511 into which the rotating shaft 3 is inserted. A substantially arc-shaped first contact portion 52 is formed on one downstream side, and a substantially arc-shaped second contact portion 53 is formed on the other upstream and downstream sides of the base portion 51 . The substantially arc-shaped first contact portion 52 extends along the inner peripheral surface 24 of the tubular body 2 , and the substantially arc-shaped second contact portion 53 extends along the inner peripheral surface 24 of the tubular body 2 . It extends in the tubular body 2 so as to extend in the opposite direction to the first contact portion 52 in the peripheral direction of the tubular body. The stopper 5 is fixed to the peripheral wall 21 of the tubular body 2 by welding such as penetration welding.

The first contact portion 52 and the second contact portion 53 of the stopper 5 are formed at positions where the valve plate 4 contacts when the rotating valve plate 4 is in a position to close the exhaust flow path of the tubular body 2. The contact surface 521 of the first contact portion 52 to the valve plate 4 and the contact surface 531 of the second contact portion 53 to the valve plate 4 close the exhaust passage of the tubular body 2. It abuts on the valve plate 4 at the position where the valve plate 4 is positioned to restrict the rotation of the valve plate 4 . FIG. 5 shows the contact between the valve plate 4, which is positioned to close the exhaust flow path of the tubular body 2, and the contact surface 521 of the first contact portion 52 and the contact surface 531 of the second contact portion 53. shows the contact area R by .

The distance L in the axial direction of the tubular body 2 between the contact surface 521 of the first contact portion 52 of the stopper 5 to the valve plate 4 and the contact surface 531 of the second contact portion 53 to the valve plate 4 is , and formed so as to be larger than the shaft diameter of the rotary shaft 3 , and the tip of the substantially arc-shaped first contact portion 52 and the tip of the substantially arc-shaped second contact portion 53 are aligned with the rotation shaft insertion hole 23 . It is arranged so as not to contact or interfere with the portion near the other end in the axial direction of the rotating shaft 3 located nearby (see FIGS. 3 and 2).

In the exhaust valve 1 of the present embodiment, the drive of the actuator 8 is controlled by the control device (not shown) to rotate the rotating shaft 3 and the valve plate 4 to switch between the open state and the closed state. In the exhaust valve 1 in the open state, the extending direction of the surfaces of the first flat plate portion 41 and the second flat plate portion 42 of the valve plate 4 is arranged so as to follow the exhaust flow path in the pipe body 2 and the pipe axial direction (Fig. 2, see Figure 3). In the exhaust valve 1 in the closed state, the first flat plate portion 41 and the second flat plate portion 42 of the valve plate 4 are arranged so as to close the exhaust flow path in the tubular body 2 , and the first flat plate portion 41 is positioned at the first flat plate portion of the stopper 5 . The contact surface 521 of the contact portion 52 abuts, and the second flat plate portion 42 abuts the abutment surface 531 of the second contact portion 53 of the stopper 5 to suppress the flow of the exhaust gas to the downstream pipe 12 as much as possible. (see Figures 1, 4 and 5).

Further, when manufacturing the exhaust valve 1 of the present embodiment, the base portion 51 formed with the insertion hole 511 into which the rotating shaft 3 is inserted, the first contact portion 52, and the second contact portion 53 are integrally formed. The stopper 5 is fitted into the tubular body 2 by aligning the insertion hole 511 of the base portion 51 of the stopper 5 of the integrally formed member with the rotating shaft insertion hole 22 formed in the peripheral wall 21 of the tubular body 2. As a result, it is possible to easily assemble while ensuring the required degree of coaxiality on the basis of the alignment of the insertion hole 511 and the rotary shaft insertion hole 22 .

According to the exhaust valve 1 of the present embodiment, the number of parts can be reduced by forming the stopper 5 as an integrally formed member, and the number of positioning fitting mechanisms for the stopper 5 and the tubular body 2 and the number of positioning and fixing processes can be reduced. By reducing the number of times, it is possible to improve manufacturing efficiency and reduce manufacturing costs. In addition, since it is only necessary to fit and assemble the stopper 5 and the tubular body 2 as one integrally formed member, it is possible to reduce the gap for fitting and positioning, and the fitting accuracy of the stopper 5 and the tubular body 2 is improved. The product accuracy after assembly can be enhanced, and the product quality of the exhaust valve 1 can be improved.

Further, the first contact portion 52 and the second contact portion 53 are each formed in a substantially arc shape, and the contact surface 521 of the first contact portion 52 to the valve plate 4 and the valve plate 4 of the second contact portion 53 By setting the distance L in the axial direction of the tubular body 2 between the contact surface 531 and the contact surface 531 to be larger than the shaft diameter of the rotating shaft 3, the first Interference and contact between the first contact portion 52 and the second contact portion 53 and the valve plate 4 and the rotating shaft 3 can be prevented, and the assembly work of the rotating shaft 3 can be facilitated. Further, the tip of the first contact portion 52 having a substantially arc shape can be extended to a position overlapping the rotation shaft 3 in the axial direction of the tubular body, so that the contact surface 521 of the first contact portion 52 and the valve plate 4 are aligned. The contact distance and area can be increased, and exhaust leakage can be suppressed as much as possible when the valve plate is closed. In addition, while the product accuracy can be improved by aligning the rotation shaft insertion hole 22 of the tubular body 2 with the insertion hole 511 of the rotation shaft 3 of the base 51, the position facing the base 51 of the stopper 5 in the tubular body 2 By arranging the substantially arc-shaped first contact portion 52 and the second contact portion 53 apart from each other, it is possible to widen the allowable range of dimensional accuracy and improve the yield.

Further, when aligning the insertion hole 511 of the rotation shaft 3 of the base 51 of the stopper 5 with the rotation shaft insertion hole 22 formed in the peripheral wall 21 of the tubular body 2 and assembling the exhaust valve on the basis of this, manufacturing work can be facilitated. In addition, the required coaxiality between the insertion hole 511 of the stopper 5 for the rotation shaft 3, the rotation shaft insertion hole 22 of the peripheral wall of the tubular body, and the rotation shaft 3 can be easily ensured. It is possible to improve the product accuracy and product quality. Further, since the required coaxiality between the insertion hole 511 of the rotating shaft 3 of the stopper 5, the rotating shaft insertion hole 22 of the peripheral wall of the tubular body, and the rotating shaft 3 can be secured more reliably, the rotating shaft 3 and the valve plate 4 Smoother rotation can be obtained by reducing friction in the rotation, and the valve plate 4 can be brought into contact with the contact surface 521 of the first contact portion 52 and the second contact with the set contact distance and contact area. The abutting surface 531 of the portion 53 can reliably abut against the valve plate, thereby minimizing leakage of the exhaust gas when the valve plate is closed.

[Scope of invention disclosed in this specification]
In addition to each invention and embodiment listed as an invention, the invention disclosed in this specification is specified by changing these partial contents to other contents disclosed in this specification within the applicable range, Alternatively, what is specified by adding other contents disclosed in this specification to these contents, or what is specified by deleting these partial contents to the extent that partial effects can be obtained and making them a broader concept contain. The invention disclosed in this specification also includes the following modifications and additional contents.

For example, the stopper 5 in the above embodiment is a substantially C-shaped integrally formed member when viewed from the front. The tip of a substantially arc-shaped first contact portion 52 extending along the inner peripheral surface 24 of the tubular body 2 and the first contact portion extending along the inner peripheral surface 24 of the tubular body 2 on the other side of the base portion 51 The tip of a substantially arc-shaped second contact portion 53 extending on the opposite side of 52 is connected to a second base portion formed with an insertion hole into which the other end portion side of the rotating shaft 3 is inserted, and is approximately approx. It is also possible to use an O-shaped integrally formed member as a stopper or the like.

In addition, the shape of the valve plate in the exhaust valve 1 of the present invention is such that the substantially semicircular first flat plate portion 41 and the substantially semicircular second flat plate portion 42 of the above embodiment are integrally connected via the curved plate portion 43. It is not limited to the formed stepped plate-shaped valve plate 4, and is suitable within the scope of the present invention.

INDUSTRIAL APPLICABILITY The present invention can be used for an exhaust valve that is installed in an exhaust passage of an automobile or the like through which exhaust gas flows, and adjusts the amount of exhaust gas flowing and the exhaust sound by opening and closing the valve.

DESCRIPTION OF SYMBOLS 1... Exhaust valve 2... Pipe body 21... Peripheral wall 22, 23... Rotating shaft insertion hole 24... Inner peripheral surface 3... Rotating shaft 4... Valve plate 41... First flat plate part 42... Second flat plate part 43... Curved plate part 5 Stopper 51 Base 511 Insertion hole 52 First contact part 521 Contact surface 53 Second contact part 531 Contact surface 61, 62 Bearing case 611, 621 Flange 71, 72 Bearing 8 Actuator 81 Drive transmission portion 11 Upstream pipe 12 Downstream pipe R Contact area due to contact between the valve plate and the contact surface of the first contact portion and the contact surface of the second contact portion L The distance in the tube axial direction between the contact surface of the first contact portion and the contact surface of the second contact portion

Claims (3)

a tubular body that connects the exhaust upstream pipe and the downstream pipe;
a valve plate mounted on a rotating shaft that rotates by driving of an actuator and arranged in the tubular body, the valve plate being rotatable to open and close an exhaust flow path in the tubular body;
comprising a stopper fixed within the tubular body;
The stopper includes a base portion formed with an insertion hole into which the rotating shaft is inserted, and a first contact portion extending along the inner peripheral surface of the tubular body on one side upstream and downstream of the exhaust gas from the base portion. and a second contact portion extending along the inner peripheral surface of the tubular body on the other side of the exhaust upstream and downstream of the base portion and on the opposite side to the first contact portion. is an integrally formed member,
An exhaust valve, wherein the valve plate contacts the first contact portion and the second contact portion at a position where the valve plate closes the exhaust passage. the valve plate is formed in a stepped plate shape in which a substantially semicircular first flat plate portion and a substantially semicircular second flat plate portion are integrally connected via a curved plate portion;
the first contact portion and the second contact portion of the stopper, which is substantially C-shaped in a front view, are each formed in a substantially arc shape;
The distance in the axial direction of the tubular body between the contact surface of the first contact portion to the valve plate and the contact surface of the second contact portion to the valve plate is equal to the axis of the rotating shaft. 2. An exhaust valve according to claim 1, characterized in that it is set larger than the diameter. A method for manufacturing an exhaust valve according to claim 1 or 2,
A base portion formed with an insertion hole into which a rotating shaft is inserted, a first contact portion extending along the inner peripheral surface of the tubular body on one side upstream and downstream of the base portion, and upstream and downstream of the base portion A substantially C-shaped stopper in front view, which is constructed by integrally forming a second contact portion along the inner peripheral surface of the tubular body and extending on the opposite side to the first contact portion on the other side of the A step of fitting the stopper into the tubular body by aligning the insertion hole of the base with the rotating shaft insertion hole formed in the peripheral wall of the tubular body connecting the upstream pipe and the downstream pipe of the exhaust gas. A method of manufacturing an exhaust valve, characterized by:

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