US20020157623A1 - Hydraulic valve actuation systems and methods - Google Patents

Hydraulic valve actuation systems and methods Download PDF

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Publication number
US20020157623A1
US20020157623A1 US10/108,246 US10824602A US2002157623A1 US 20020157623 A1 US20020157623 A1 US 20020157623A1 US 10824602 A US10824602 A US 10824602A US 2002157623 A1 US2002157623 A1 US 2002157623A1
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Prior art keywords
valve
spool
engine
pressure
proportional
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Christopher Turner
Miguel Raimao
Guy Babbitt
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L9/00—Valve-gear or valve arrangements actuated non-mechanically
    • F01L9/10—Valve-gear or valve arrangements actuated non-mechanically by fluid means, e.g. hydraulic
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01L—CYCLICALLY OPERATING VALVES FOR MACHINES OR ENGINES
    • F01L2800/00—Methods of operation using a variable valve timing mechanism
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B2275/00—Other engines, components or details, not provided for in other groups of this subclass
    • F02B2275/32—Miller cycle
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention relates to the field of hydraulic valve actuation for internal combustion engines.
  • piston-type internal combustion engines of interest to the present invention are currently widely used in automobiles, trucks, buses and various other mobile and stationary power systems.
  • Such engines include the common gasoline and diesel engines, as well as similar engines operating from different fuels such as liquid propane.
  • These engines commonly utilize intake and exhaust valves that are spring loaded to the closed position and which are directly or indirectly opened at appropriate times by a camshaft driven from the engine crankshaft.
  • a camshaft driven from the engine crankshaft In a two-cycle engine such as a two-cycle diesel engine, the camshaft will rotate in synchronism with the engine crankshaft, though in a four-cycle engine, the camshaft is driven through a two-to-one reduction drive system (gear or chain or belt, etc.) to rotate at one-half the engine crankshaft speed.
  • Camshaft actuation of engine valves historically has had a number of advantages, resulting in its relatively universal use in such engines for many decades. These advantages include high reliability, particularly given the current level of development of such cam actuated valve systems. Cam actuation is also relatively cost effective, again given the state of development and quantities in which it is produced. Cam actuation also has the advantage of allowing shaping the cam to provide a smooth curve defining valve position versus camshaft angle. This results in a rather low velocity takeoff and initial valve opening, as well as a rather low velocity valve final closing at low engine speeds, resulting in minimum noise being generated. It also results in faster valve opening and valve closing at higher engine speeds as required to maintain the same valve timing throughout the engine speed operating range.
  • Cam actuated valve systems also have certain limitations which are becoming of increasing concern.
  • optimal valve timing is not fixed throughout the engine operating range. For instance, valve timing for maximum power at one engine speed will not be the same as valve timing for maximum power at another engine speed. Accordingly, the classic cam operated valve systems utilize a compromise valve timing, providing reasonable performance over a reasonable range of engine operating conditions while being less than optimal for most, if not at all, these conditions. Further, valve timing for maximum power at any engine speed may not be optimal from an engine emissions standpoint. Optimum valve timing at any given engine speed may need to be dependent on engine loading, and perhaps other parameters, such as air temperature, air pressure, engine temperature, etc.
  • Hydraulic engine valve actuation systems and methods for internal combustion engines utilize a proportional valve to regulate the flow of a working fluid to and from a hydraulic actuator controlling the engine valve position.
  • the position of the proportional valve is controlled by high speed valves to control various engine valve parameters, including engine valve takeoff and landing velocities. Returning all valves to a known starting position between engine valve events avoids accumulation of errors in proportional valve positioning.
  • Embodiments using spool valves for the high speed valves and the proportional valve, and spring return and hydraulic return for the engine valve, are disclosed.
  • a specially shaped spool in the proportional valve may be used to shape the flow areas versus spool position. This allows more gradual restricting of the flow areas versus spool movement over selected portions of the possible spool positions, diminishing the effect of small errors in spool position in such regions without inhibiting the maximum flow areas when the spool is at its maximum positions.
  • FIG. 1 is a block diagram of an exemplary configuration of a system in accordance with the present invention.
  • FIG. 2 is a diagram illustrating the general structure and function of the three-way proportional spool valve 24 of FIG. 1.
  • FIG. 3 is a perspective view of the spool 38 of the proportional valve of FIG. 2.
  • FIG. 4 is an expanded view of an edge of the center land of the spool 38 of FIG. 3.
  • FIGS. 5 and 6 are graphical representations of the flow area versus spool position provided by the proportional valve 24 between the high pressure rail and the chamber 26 of the valve actuator, and between the chamber 26 and the vent 37 , respectively.
  • FIG. 7 is a cross sectional view of an engine valve actuator consisting of two concentric pistons that may be used with the present invention.
  • FIG. 8 is a diagram of an embodiment of the present invention that controls a hydraulically returned engine valve using a closed center 3-way proportional valve.
  • FIG. 9 is a diagram of an embodiment of the present invention that controls a hydraulically returned engine valve using a closed center 4-way proportional valve.
  • the present invention is a hydraulic valve operating system for operating one or more intake valves or one or more exhaust valves in a piston-type internal combustion engine, which provides full flexibility in valve timing, valve duration, extent of opening, and valve opening and closing velocity. Operation over the desired range of these and other parameters may be controlled, and more importantly optimized, for all engine operating conditions. Such optimization may also include incrementally adjusting the valve operation based on the valve operation during a previous valve operating cycle. This is achieved by controlling the position of a proportional valve by the use of pilot valves to control the operating parameters of an intake or exhaust valve.
  • intake valve or an “exhaust valve”
  • exhaust valve unless otherwise made clear by the context in which the phrase is used, shall mean one or more intake valves for a cylinder of an internal combustion engine, or one or more exhaust valves of a cylinder of an internal combustion engine.
  • Exemplary embodiments of this system sometimes referred to herein as a “two-stage” system, are hereafter described in detail.
  • FIG. 1 a block diagram of an exemplary configuration of a system in accordance with the present invention may be seen.
  • the system illustrated in FIG. 1 may be used to actuate an intake or an exhaust valve.
  • This 2-stage system consists of 2 miniature 2-way digital latching spool valves 20 and 22 coupled to control the position of a 3-way proportional spool valve 24 .
  • the proportional spool valve controls the flow area into, and out of, a control volume 26 .
  • This control volume acts on an actuator 28 to regulate the position of the engine valve 30 .
  • a spring return 32 is utilized for valve closing, though embodiments with hydraulic valve closing may also be used, as shall be subsequently described.
  • the 2 miniature 2-way digital latching spool valves 20 and 22 may preferably be identical valves, preferably in accordance with the 2 way valves disclosed in U.S. Pat. No. 5,640,987 entitled Digital Two, Three, and Four Way Solenoid Control Valves, issued Jun. 24, 1997, the disclosure of which is incorporated herein by reference.
  • Such valves are double solenoid, high speed, magnetically latching spool valves, that as used in the present invention, are operable between two positions. The first position couples a first port to a second port for fluid communication between the two ports, and the second position blocks fluid communication between the first and second ports.
  • valves generally of the type disclosed in the above referenced patent are preferred because of their very high speed for good control, and low energy consumption because of such capabilities as their magnetic latching, and the ability to sense completion of actuation, if used, to minimize heating above the already relatively warm environment in which they operate. (See U.S. Pat. Nos. 5,720,261 and 5,954,030.)
  • valve 20 allows fluid flow from fluid line 34 to a drain line or reservoir 37 (at a relatively low pressure, such as atmospheric pressure) when in its first position, and blocks fluid flow from fluid line 34 to the drain 37 when in its second position.
  • Valve 22 allows fluid flow from a low pressure rail 36 to the fluid line 34 when in its first position, and blocks fluid flow from the low pressure rail 36 to the fluid line 34 when in its second position.
  • Check valve 23 is optional, and is normally closed, as the differential pressure on the check valve normally will not be in a direction to open the valve. Its presence however, will help damp transient pressure fluctuations and recover energy in the pressure fluctuations.
  • FIG. 2 a diagram illustrating the general structure and function of the three-way proportional spool valve 24 of FIG. 1 may be seen.
  • the proportional spool valve includes a spool 38 within an internal housing 40 which fits within an external housing assembly (not shown) with O-rings in O-ring grooves 42 to separate the regions of ports 1 , 2 and 3 from each other and from the ends of the internal housing 40 .
  • the outer housing assembly in addition to having the associated fluid connections, also includes internal annual grooves adjacent each of the regions identified as ports 1 , 2 and 3 in FIG.
  • Fluid communication from each of the ports to the associated inner region 44 , 46 or 48 is provided in the exemplary embodiment not only by through holes 50 , but also by cooperatively disposed orthogonal through holes 52 associated with each of the ports.
  • the spool 38 is positioned within the internal housing 40 by fluid pressures acting on a piston at the left end of the spool having an effective area Al and a piston at the right side of the spool having an effective area of A 2 .
  • the spool 38 is shown in its extreme right position, referred to herein as its first position, as defined by stops on the travel of either the pistons actuating the spool or stops acting on the spool itself. In this position, the spool 38 is blocking fluid communication between ports 3 and 2 and is allowing fluid communication between ports 2 and 1 .
  • the spool is at its left-most position, referred to herein as its second position, fluid communication between ports 1 and 2 is blocked and fluid communication between ports 2 and 3 is enabled.
  • FIG. 3 is a perspective view of the spool 38 and FIG. 4 is an expanded view of an edge of the center land of the spool 38 . As may be seen in FIG.
  • the center land on the spool has a plurality of kerfs 54 equally spaced around each end of the center land, which kerfs begin to open a controlled flow area with spool position prior to the edge of the land on the spool reaching the edge of the land on the internal housing, the normal position for a spool valve flow area starting to be established.
  • each end of the center land of the exemplary spool has additional diameters D 1 , D 2 and D 3 , where D 3 is less than D 2 , D 2 is less than D 1 and D 1 is less than D 0 .
  • This provides a non-linear variation in flow area versus spool position during the opening and closing of the fluid communication between adjacent ports, as illustrated in FIGS. 5 and 6.
  • FIG. 5 shows the flow area between ports 1 and 2 , and ports 2 and 3 , respectively, versus the position of the spool in the three-way proportional spool valve.
  • FIG. 5 shows the flow area between ports 1 and 2 , which is a mirror image of FIG. 5.
  • the reduction in flow area on the initial valve closing motion of the spool occurs at a high rate with respect to spool position, decreasing in change in flow rate with an increasing position of the spool until the flow area goes to substantially zero when less than half of the spool motion has been achieved, thereby substantially altering the flow area versus spool position characteristic of a conventional spool valve. Also, because the flow area goes to substantially zero before one-half of the maximum spool travel has been achieved, fluid communication between both ports 1 and 2 , and ports 2 and 3 , is disabled or blocked when the spool is approximately centered within its travel range.
  • the substantial blockage between both ports 1 and 2 , and ports 2 and 3 occurs whenever the spool's position is anywhere between approximately 40% of its travel and 60% of its travel.
  • other shaping of the flow areas, or no shaping may be used if desired, though preferably some shaping will be used to diminish the effect of small errors in spool position in the restricted regions without inhibiting the maximum flow areas when the spool is at its maximum positions.
  • fluid in the low pressure rail 36 which may have a pressure, by way of example, of 20 to 50 bar, is coupled to the right side of the three-way proportional spool valve 24 to act on the area A 2 (FIG. 2) of a piston encouraging the spool to its left-most position.
  • valve 30 is half open and spool valves 20 and 22 are both closed, then port 2 of the proportional spool valve will be isolated from both ports 1 and 3 , so that the fluid in the control volume 26 is trapped, maintaining the valve 30 at its present position.
  • the two-way spool valves 20 and 22 are very high speed valves, they may be controlled in such as manner as to rapidly controllably place the spool of the proportional spool valve at any desired location within the extremes of its travel, and thus variably control the flow rate of fluid into or out of the control volume 26 .
  • This allows full control of the operating parameters of the valve 30 , such as the extent of opening, the timing and duration of opening, the velocity profile of the opening and closing of the valve (which profiles can be different from each other and/or vary with engine operating conditions), and the final valve closing velocity with engine rpm.
  • This allows a relatively low velocity valve closing at low engine rpm for low noise operation, while still allowing the closing velocity to be increased with engine rpm, as necessary for higher engine operating speeds.
  • the fluid used in the exemplary embodiment in the low pressure rail, the high pressure rail and passed to drain is engine operating oil, though other fluids may be used if desired. Since the flow rates in the control system for valve 30 will vary with various parameters, such as oil viscosity, and thus oil temperature, and the pressure of the low pressure rail and the high pressure rail, operation of the valve control system of FIG. 1 must reasonably compensate for such variations. As a first order approximation, these variations may be reasonably modeled so that the control system as shown in FIG.
  • valves 20 and 22 can reasonably vary operating durations of valves 20 and 22 to at least approximate the desired profile of the proportional valve spool position with engine crankshaft angle, given the existing engine operating parameters (speed, engine load, fuel temperature, air temperature, engine oil temperature, atmospheric pressure, etc.).
  • a small Hall effect sensor 58 is positioned adjacent actuator 28 for the valve 30 so as to provide a feedback signal to the controller.
  • valve motion during a valve operating cycle may be monitored and used to control the operation of the valves 20 and 22 for that valve operating cycle, and/or to make corrections in the next valve operating cycle to more accurately achieve optimum valve operation for that valve operating cycle.
  • more optimum operation may be determined in any of various ways, including better compliance to a predetermined valve position profile versus engine crank angle as predetermined for the then existing engine operating conditions and ambient conditions, or as determined by the effect of incremental changes on one or more engine performance characteristics for the change in valve operation just made, or a combination of both.
  • a sensor such as a position sensor (Hall effect sensor or other position sensor) may be used on only one of the valves, or on both valves, the sum of the signals providing a better average indication of the position profile of the two valves and the difference in the signals providing fault detection, such as a sticky valve. While a position sensor(s) is preferred, other types of sensors could be used, such as a velocity sensor, as the integration times to convert to position are short.
  • State 1 The high pressure fluid from the high pressure rail 56 (approximately 100-240 bar) is allowed to flow from the high pressure rail to a control volume 26 above the engine valve actuation piston.
  • State 2 The spool 38 of the proportional valve is centered between its hard stops, trapping fluid in the control volume above the engine valve actuation piston and creating a hydraulic lock.
  • State 3 The fluid in the control volume 26 above the engine valve actuation piston is vented to atmospheric pressure.
  • An exemplary valve event may be described as follows. Initially the supply pilot valve 22 is open and the vent pilot valve 20 is closed (as illustrated in FIG. 1). This keeps the proportional valve spool in the venting (rightmost) position (State 3, FIGS. 5 & 6). Specifically, the flow area between engine valve actuation piston control volume 26 and vent 37 is at a maximum (state 3, FIG. 6) and the area between engine valve actuation piston control volume and the high-pressure rail is closed (state 3, FIG. 5). As a result, the engine valve is forced closed against its seat by the return spring 32 .
  • vent pilot valve 20 is opened once again so that the proportional spool moves to a position that opens a larger flow area between the high pressure rail and the engine valve actuation piston's control volume. This results in a rapid opening of the engine valve after the initial slow takeoff.
  • the supply pilot valve 22 will be opened again long enough to move the proportional valve to the high gain region of state 3, and then closed, at least before vent pilot valve 20 is again opened.
  • the flow area between the engine valve control volume 26 and vent 37 is a maximum. Therefore, the engine valve will accelerate very quickly toward its seat via the stored energy in the valve spring.
  • the flow area that connects the engine valve control volume 26 and vent 37 must be restricted. This can be achieved by once again opening the vent pilot valve 20 for a short period to reposition the proportional valve to a low gain in state 3. This seating velocity will change depending on where the proportional valve is stopped in this region.
  • the valve actuator comprises a piston 64 having a cross-sectional area A 1 on a piston rod 66 having a cross-sectional area A 2 .
  • Chamber 68 is permanently coupled to the high pressure rail, and chamber 70 is switchable by the proportional valve between the high pressure rail and the vent. Consequently, the maximum valve opening force is equal to the pressure of the high pressure rail times A 2 and the maximum valve closing force is equal to the pressure of the high pressure rail times A 1 ⁇ A 2 . Because of the functional relationship between spring force and stroke, one can achieve essentially the same valve dynamics as a hydraulically returned valve with a smaller diameter actuator.
  • the hydraulically returned system can also be constructed using a closed center 4-way proportional valve (FIG. 9). Like the closed center 3-way proportional valve, its position can also be infinitely varied throughout 3 flow states.
  • State 1 The high pressure fluid is allowed to flow from the high pressure rail to a control volume 70 above the engine valve actuation piston 64 while the fluid in chamber 68 acting below the engine valve actuation piston 64 is vented to tank.
  • State 2 The proportional valve is centered between its hard stops, trapping fluid in the control volume 70 above the engine valve actuation piston and in the control volume 68 below the engine valve actuation piston, thus creating a hydraulic lock.
  • State 3 The fluid in the control volume 70 above the engine valve actuation piston is vented to atmospheric pressure while high pressure fluid is allowed to flow from the high pressure rail to the control volume 68 below the engine valve actuation piston 64 .
  • the proportional valve uses hydraulic force to oppose the pressure in its control volume.
  • the proportional valve can also use a spring to supply part or all of the opposing force.
  • the present invention has many advantages for both diesel and gasoline engines, as well as similar engines powered with alternate fuels. These advantages include:
  • the proportional 3 or 4 way valve has low gain flow regions for fine control at valve take-off and seating. It also has high gain flow regions for maximum flow allowing increased speed of the engine valve so that airflow into the engine cylinders can be maximized.
  • the system can allow the engine valve profile to be non-symmetric.
  • the system is capable of an infinitely varying the slew rate of the engine valve independent of rail pressure.
  • the system does not require a slow take-off and landing. Specifically, the valve can begin opening with maximum acceleration or seat at maximum velocity if desired.
  • the system does not need a lash adjustment system, specifically:
  • the system is unaffected and can compensate for engine valve recession due to wear of the valve seat and the engine valve, and
  • the system is unaffected and can compensate for tolerance stack up between valve train components resulting from initial assembly and manufacturing tolerances.
  • the system can compensate for varying working fluid viscosity due to temperature, age, etc.
  • the system can be operated in such a way that engine braking will result, specifically by shutting off the injector during braking and opening the exhaust valve at the top of the compression stroke to dissipate the compression energy.
  • the engine cycle can be varied to allow for:
  • the system can allow for internal exhaust gas recirculation (EGR). As a result the EGR valve can be removed.
  • EGR exhaust gas recirculation
  • the system will operate more efficiently with a sequentially apportioned pump.
  • the low-pressure rail can be replaced with an accumulator that is supplied by the return flow of the engine valve actuator.
  • the throttle body can be eliminated.
  • This 2-stage system has the capability of satisfactorily controlling engine valves at very high engine speeds (from idle speeds to 10,000 RPM).
  • the critical regions of valve take-off and seating can be controlled with accuracy and precision while providing the features of infinitely variable valve timing, duration and lift.
  • the system also has the capability of significantly increasing the amount of air that can be supplied to an engine's cylinders throughout the full range of engine speed by adjusting valve timing and duration to maximize the dynamic effects of flow into and out of the combustion chamber at all engine speeds.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Valve Device For Special Equipments (AREA)
  • Magnetically Actuated Valves (AREA)
  • Fluid-Pressure Circuits (AREA)
US10/108,246 2000-12-04 2002-03-25 Hydraulic valve actuation systems and methods Abandoned US20020157623A1 (en)

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US10/108,246 US20020157623A1 (en) 2000-12-04 2002-03-25 Hydraulic valve actuation systems and methods

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EP (1) EP1409853B1 (enExample)
JP (1) JP2004515681A (enExample)
AU (1) AU2002225937A1 (enExample)
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DE60118984T2 (de) 2007-01-11
EP1409853A2 (en) 2004-04-21
JP2004515681A (ja) 2004-05-27
WO2002046582A2 (en) 2002-06-13
AU2002225937A1 (en) 2002-06-18
WO2002046582A3 (en) 2003-01-16
DE60118984D1 (de) 2006-05-24
EP1409853B1 (en) 2006-04-19

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