Technical Field
[0001] The present invention relates to a phase varying device of an engine of an automobile
that transmits rotation of a crankshaft of the automobile engine to a camshaft for
opening/closing an intake valve or an exhaust valve of the engine and varies open/close
timing of the intake valve or the exhaust valve according to an operating condition
such as an engine load and revolutions.
Background Art
[0002] As this type of phase varying device, one as disclosed in the following Patent Document
1 proposed by the present inventor et al. has been known. This is shown in FIG. 7.
[0003] The phase varying device is used in a manner fitted to an unillustrated engine case
(a cover for the phase varying device) since the intake valve or the exhaust valve
is opened/closed, and includes an annular outer casing section 10 having a sprocket
12 to which a driving force of a crankshaft of an engine is transmitted by an unillustrated
chain, an annular inner casing section 20 arranged coaxially with the outer casing
section 10, capable of rotating relatively to the outer casing section 10, and forming
a part of a camshaft 2, an intermediate member 30 interposed between the outer casing
section 10 and the inner casing section 20 while being respectively engaged with the
outer casing section 10 and the inner casing section 20 through helical splines and
moving in an axial direction thus varying the phase of the inner casing section 20
with respect to the outer casing section 10, and an electromagnetic brake 40 being
an electromagnetic control means provided at a side of the inner casing section 20
opposite the side where the camshaft 2 is disposed and moving the intermediate member
30 in the axial direction. On the camshaft 2, provided is a cam 2a for opening/closing
one of the intake valve or exhaust valve.
[0004] The outer casing section 10 is composed of the sprocket 12 provided with a ring-shaped
concave portion 13 at an inner periphery thereof, an inner flange plate 14 closely
adhered to a side surface of the sprocket 12 and designing a flange engagement groove
13A in cooperation with the concave portion 13, and a spline case 16 fixing the inner
flange plate 14 to the sprocket 12 by tightening together and formed with a spline
engagement portion 17 with the intermediate member 30 at an inner circumference thereof.
By a large-diameter concave portion at an opening side of the concave portion 13 of
the outer casing section 10 and a small-diameter concave portion 13b at an inner side
of the concave portion 13, a step portion 13c facing directly to an outer periphery
of a flange 24 at the side of the inner casing section 20 is provided between both
concave portions 13a and 13b. The sprocket 12, inner flange plate 14, and spline case
16 are integrated by a tightening screw 11, which therefore facilitates formation
of the flange engagement groove 13A and the spline engagement portion 17 in the spline
case 16.
[0005] In addition, a small-diameter sprocket 12A is fixedly fitted to the outer casing
section 10, and although not illustrated, the small-diameter sprocket 12A is coupled
with a sprocket of the phase varying device for opening/closing the other of the intake
valve or exhaust valve by a chain, for controlling both the intake valve and exhaust
valve.
[0006] Meanwhile, female and male helical splines 32 and 33 are provided on inner and outer
circumferential surfaces of the intermediate member 30, male helical splines 23 are
provided on an outer peripheral surface of the inner casing section 20, and female
helical splines are formed at the spline engagement portion 17 of an inner circumferential
surface of the spline case 16. Moreover, the inner and outer splines 32 and 33 of
the intermediate member 30 are provided as helical splines in opposite directions
so that a slight movement of the intermediate member 30 in the axial direction can
greatly vary the phase of the inner casing section 20 with respect to the outer casing
section 10. A male screw portion 31 is formed on the outer circumferential surface
of the intermediate member 30.
[0007] The electromagnetic brake 40 is composed of an electromagnetic clutch 42 for which
an electromagnet (electromagnetic coil) 62 is provided in a clutch case 60 and a friction
material 66 is fixedly fitted to the clutch case surface, a rotary drum 44 made of
a ferromagnetic material for receiving a braking force from the friction material
66 of the electromagnetic clutch 42, and a torsion coil spring 46 axially interposed
between the rotary drum 44 and the outer casing section 10. Pins 68 are engaged with
holes provided in the engine case, so that the electromagnetic clutch 42 is supported
on the engine case so as to be movable in the axial direction but not be rotatable.
The rotary drum 44 is supported so as to be rotatable on the inner casing section
20 by a bearing 22 and is formed with a female screw portion 45 to be screwed with
the male screw portion 31 of the intermediate portion 30. When the rotary drum 44
rotates relatively to the outer casing section 10, the intermediate member 30 moves
in the axial direction as a result of the work of both screw sections 45 and 31.
[0008] When the electromagnetic clutch 42 is off, since the braking force does not work
on the rotary drum 44, the rotary drum 44 and outer casing section 10 are fixed at
their initial positions by the torsion coil spring 46, the outer casing section 10,
inner casing section 20, intermediate member 30, and rotary drum 44 integrally rotate,
and no phase difference occurs between the outer casing section 10 and the inner casing
section 20. Then, since the inner casing section 20 has been coupled to the camshaft
2 and the outer casing section 10 has been coupled with a crank pulley provided on
the crankshaft by a chain, the intake valve or exhaust valve can be opened/closed
at a normal timing according to rotation of the crankshaft.
When the electromagnetic clutch 42 is turned on, a frictional braking force acts on
the friction material 66 provided on the electromagnetic clutch 42 and the rotary
drum 44. When the braking force acts on the rotary drum 44, the rotary drum 44 experiences
a rotational delay with respect to the outer casing section 10, the intermediate member
30 moves rightward in FIG. 7 as a result of the work of the spring portions 31 and
45, and owing to the inner and outer helical splines 32 and 33 of the intermediate
member 30, the inner casing section 20 rotates relatively to the outer casing section
10, so that the phase difference between both varies. Then, the rotary drum 44 is
held at a position where the braking force balances with a spring force of the torsion
coil spring 46. By controlling current to be supplied to the electromagnet of the
electromagnet clutch 42, the inner casing section 20 and outer casing section 10 can
be controlled to have a desired phase difference. Thereby, the open/close timing of
the intake valve or exhaust valve can be appropriately varied.
[0009] When the electromagnetic clutch 42 is again turned off, the braking force no longer
works on the rotary drum 44, the intermediate member 30 rotates to its initial position
as a result of the action of the torsion coil spring 46 and moves leftward in FIG.
7 to the initial position as a result of the work of the screw portions 31 and 45.
Then, the inner casing section 20 rotates to an initial position in a reverse direction
with respect to the outer casing section 10 to eliminate the phase difference between
both, and the intake valve or exhaust valve is opened/closed at a normal timing.
[0010] Meanwhile, friction torque adding members 51 and 55 are interposed between the flange
24 of the inner casing section 20 and sides of the flange engagement groove 13A of
the outer casing section 10 so as to increase friction torque of a relative sliding
portion between the outer casing section 10 and the inner casing section 20 and suppress
gear rattle of the tooth portions hitting against each other from occurring at the
helical spline engagement portions 23, 32, 33, and 17 between the intermediate member
30 and the outer casing section 10 and inner casing section 20.
[0011] Moreover, the phase varying device is internally supplied with engine oil through
an inlet 73a of the camshaft 2, an oil channel in the camshaft 2, and an outlet 73b.
The engine oil that has exited the outlet 73b is supplied to a sliding surface between
the friction material 66 provided on the surface of the electromagnetic clutch 42
and the rotary drum 44 so as to prevent overheating between the friction material
66 and the rotary drum 44 owing to friction (see the following Patent Document 1 for
details).
Patent Document 1:
Japanese Published Unexamined Patent Application No. 2002-371814.
Disclosure of the Invention
Problems to be Solved by the Invention
[0012] As described above, in the abovementioned phase varying device, when the sliding
surface temperature reaches a high temperature owing to frictional heat on the relative
sliding surface between the friction material 66 and the rotary drum 44, there is
a possibility that the surface of the friction material generally formed of a porous
material clogs up with reactants and insoluble contents of additives such as an antioxidant,
a friction adjuster, and a detergent/dispersant dispersed in the engine oil and friction
torque generated at the friction material 66 and rotary drum 44 is lowered, so that
a cooling mechanism to allow the engine oil to flow between the friction material
66 and the rotary drum 44 is indispensable. Since the cooling mechanism is formed,
the phase varying device has a complicated structure, thus resulting in a high cost,
wherein a problem resides.
[0013] The present invention has been made in view of the problems described above and an
object thereof is to prevent heat generation owing to friction in a phase varying
device of an automobile engine.
Means for Solving the Problems
[0014] In order to achieve the aforementioned object, according to a first aspect of the
invention, in a phase varying device of an engine including: an outer casing section
having a sprocket to which rotation of a crankshaft of the engine is transmitted;
an inner casing section capable of rotating relatively to the outer casing section
and coupled with a camshaft for opening/closing an intake valve or an exhaust valve
of the engine; and an intermediate member meshing with the outer casing section and
the inner casing section through helical splines, relative rotation being generated
between the outer casing section and the inner casing section by moving the intermediate
member in an axial direction thus varying an open/close timing of the intake valve
or the exhaust valve, the phase varying device of an engine is provided with an electromagnetic
control means having a rotary drum being screwed on the intermediate member and provided
as a permanent magnet and an electromagnetic clutch for braking the rotary drum.
[0015] According to a second aspect of the invention, in the first aspect of the invention,
a plurality of magnetic poles are formed on the rotary drums, and by arranging electromagnets
in the electromagnetic clutch so that magnetic poles corresponding to the magnetic
poles are also formed and changing polarity of the electromagnets with an appropriate
phase relative to the magnetic poles of the rotary drum, the rotary drum is braked
or accelerated.
[0016] According to a third aspect of the invention, in the first or second aspect of the
invention, the electromagnetic clutch is disposed in proximity to an interior side
surface of the rotary drum.
[0017] According to a fourth aspect of the invention, in the first or second aspect of the
invention, only a vicinity of an outer circumference of the rotary drum is magnetized,
and the electromagnetic clutch is arranged in proximity to the vicinity of the outer
circumference of the rotary drum.
Effects of the Invention
[0018] By the phase varying device according to the first aspect of the invention, since
the rotary drum is braked by an electromagnetic force between the electromagnets of
the electromagnetic clutch and the rotary drum being a permanent magnet, no friction
material is necessary. In addition, since the phase varying device never reaches a
high temperature owing to frictional heat resulting from contact between the friction
material of the electromagnetic clutch and the rotary drum, an effect to reduce deterioration
of an engine oil is provided. In addition, no cooling mechanism for the electromagnetic
clutch and rotary drum is necessary, so that not only is the structure simplified,
but also malfunction hardly occurs and life is prolonged. Furthermore, for the phase
varying device, the engine oil for cooling can be reduced, and no friction material
is necessary, which is economical.
[0019] By the second aspect of the invention, furthermore, a plurality of magnetic poles
are formed on the rotary drums, and by arranging electromagnets in the electromagnetic
clutch so that magnetic poles corresponding to the magnetic poles are also formed
and changing polarity of the electromagnets with an appropriate phase relative to
the magnetic poles of the rotary drum, a suction force or a repulsive force can be
freely continuously generated between the electromagnetic clutch and the rotary drum,
so that the rotary drum is freely braked or accelerated. Therefore, in the phase varying
device, since the electromagnetic clutch 42 allows both braking and acceleration of
the rotary drum 44, a torsion coil spring to return the rotary drum 44 to its initial
position is no longer necessary, and the number of components can be reduced.
[0020] By the third aspect of the invention, furthermore, since the electromagnetic clutch
is disposed in proximity to an interior side surface of the rotary drum, the entire
length of the phase varying device can be made shorter than that of the conventional
device where the electromagnetic clutch is disposed in proximity to an exterior side
surface of the rotary drum. In addition, when the entire length the same as that of
the conventional art is allowable, the moving range of the intermediate member in
the axial direction can be increased, so that the phase can be varied in a wider range
than that of the conventional art.
[0021] By the fourth aspect of the invention, furthermore, since only a vicinity of an outer
circumference of the rotary drum is magnetized and the electromagnetic clutch is arranged
in proximity to the vicinity of the outer circumference of the rotary drum, the entire
length of the phase varying device can be further shortened. In addition, since the
electromagnetic clutch is not provided lateral to the rotary drum, the rotary drum
can also be reduced in diameter to reduce the moment of inertia so as to improve the
phase varying device in responsiveness. Furthermore, even when the rotary drum moves
in an axial direction, the rotary drum and electromagnetic clutch are always kept
at an equal distance, so that highly accurate and stable phase control becomes possible.
Best Mode for Carrying Out the Invention
[0022] Now, embodiments of the present invention will be described based on drawings.
[0023] A first embodiment according to an electromagnetic brake of a phase varying device
of the present invention is shown in FIG. 1 and FIG. 2. FIG. 1(A) is a longitudinal
sectional view of the phase varying device, FIG. 1(B) is a front view of a rotary
drum 44 of the phase varying device, and FIG. 1(C) is a front view of an electromagnetic
clutch 42 of the phase varying device. FIG. 2 is a diagram showing a current supplying
circuit to electromagnets 62 of the electromagnetic clutch 42.
[0024] The phase varying device of the present embodiment is the same as the abovementioned
conventional phase varying device except for an electromagnetic control means 40a
formed of the rotary drum 44 and electromagnetic clutch 42 to be described later and
the current supplying circuit to the electromagnets 62 to be also described later.
In the following, with respect to the present embodiment, description will be given
of the electromagnetic control means 40a and current supplying circuit to the electromagnets
62 while description of parts the same as those in the conventional device will be
omitted.
[0025] In the electromagnetic control means 40a of the phase varying device, as shown in
FIG. 1 (B), the rotary drum 44 is provided as a permanent magnet strongly magnetized
toward an axial direction so that six magnetic poles N and S of an alternate N-pole
and S-pole appear along a circumferential direction, and as shown in FIG. 1(C), the
electromagnetic clutch 42 is arranged in proximity to an exterior side surface of
the rotary drum 44, and the three electromagnets (electromagnetic coils) 62 connected
in series are arranged in a clutch case at positions corresponding to the magnetic
poles N and S of the rotary drum 44 along a circumferential direction. Moreover, the
electromagnetic control means 40a is not provided with a torsion coil spring to urge
the rotary drum 44 to its initial position, and furthermore, the electromagnetic clutch
42 is not movable in axial and radial directions with respect to the engine case 58
or not provided with a friction material that slidingly contacts the rotary drum 44.
[0026] The current supplying circuit to the electromagnets 62 is formed of, as shown in
FIG. 2, four current controllers (transistors) 64a to 64d that control a current supplied
from a power source Vcc to the electromagnets 62 and a controller 65 that sends control
signals to the respective current controllers 64a to 64d. By alternately turning on
and off a pair of the current controllers 64a and 64d located diagonally to each other
and another pair of current controllers 64b and 64c located diagonally to each other
by the control signals from the controller 65, polarity of the electromagnets can
be alternately changed. At this time, when a relative phase of the electromagnets
62 to the magnetic poles N and S of the rotary drum 44 is detected with an unillustrated
appropriate rotation detection sensor so as to synchronize polarity switching of the
current supplied to the electromagnets 62 with rotation of the rotary drum 44 and
carry out control with an appropriate phase (a phase lag or a phase lead) relative
to the magnetic poles N and S, it is possible to make only either a suction force
or a repulsive force work continuously between the respective magnets 62 and the rotary
drum 44, whereby the rotary drum 44 can be freely braked or accelerated.
[0027] In addition, to the controller 65, signals from unillustrated rotation detection
sensors respectively provided on an unillustrated crank pulley and camshaft 2 have
been received, and the controller 65 detects a phase of the camshaft 2 with respect
to the crank pulley. And, the controller 65 calculates a command phase difference
according to engine revolutions, an accelerator position, and the like so as to control
the phase of the camshaft 2 with respect to the crank pulley. Namely, the controller
65 sends control signals to the respective current controllers 64a to 64d to brake
or accelerate the rotary drum 44 until the phase difference between the crank pulley
and camshaft 2 equals the command phase difference and controls the phase difference
between the crank pulley and camshaft 2 so as to coincide with the command phase difference
. The rotation detection sensor used here to detect a phase of the camshaft 2 with
respect to the crank pulley can also be used as a phase detection sensor of the electromagnets
62 to the magnetic poles N and S of the rotary drum 44 described above.
[0028] According to the phase varying device of the present embodiment, since the rotary
drum 44 is braked or accelerated by a suction force or a repulsive force between the
electromagnets 62 of the electromagnetic clutch 42 and the rotary drum 44, no friction
is generated between both, and therefore no friction material is necessary for the
electromagnetic clutch 42. In addition, according to the phase varying device, since
the electromagnetic control means 40a never reaches a high temperature owing to frictional
heat, no cooling mechanism is necessary, so that the structure is also simplified,
and malfunction hardly occurs and life is prolonged. Moreover, engine oil for cooling
can be reduced, and no friction material is necessary, which is economical. Furthermore,
since the electromagnetic clutch 42 allows both braking and acceleration of the rotary
drum 44, a torsion coil spring to return the rotary drum 44 to its initial position
is no longer necessary, and the number of components can be reduced.
[0029] In FIG. 3, a second embodiment according to a phase varying device of the present
invention is shown. FIG. 3 (A) is a longitudinal sectional view of the phase varying
device, FIG. 3(B) is a front view of a rotary drum 44 of the phase varying device,
and FIG. 3(C) is a front view of an electromagnetic clutch 42 of the phase varying
device.
[0030] The phase varying device is, as shown in FIG. 3(A), different from the aforementioned
first embodiment in the arrangement of the electromagnetic clutch 42 and rotary drum
44 and the attaching method to an engine case 58. Namely, the electromagnetic clutch
42 is arranged in proximity to an interior side surface of the rotary drum 44 and
is supported on a shaft portion 44a of the rotary drum 44 via a bearing 43 or the
like. Furthermore, a pin 42a provided on the electromagnetic clutch 42 is engaged
with a rotation preventing groove 58a of the engine case 58 to restrict the electromagnetic
clutch 42 from rotating. As a result of the engagement between the rotation preventing
groove 58a and the pin 42a, the electromagnetic clutch 42 can move in an axial direction
while keeping a distance from the rotary drum 44 fixed. Other aspects are the same
as those of the aforementioned first embodiment.
[0031] According to the phase varying device of the present embodiment, since the electromagnetic
clutch 42 is arranged inside the rotary drum 44, the entire length can be made shorter
than that of the aforementioned first embodiment. In addition, since the electromagnetic
clutch 42 keeps the distance from the rotary drum 44 fixed, a braking force or an
accelerating force applied to the rotary drum 44 is kept fixed, so that highly accurate
and stable phase control becomes possible.
[0032] In FIG. 4, a third embodiment according to a phase varying device of the present
invention is shown. FIG. 4 (A) is a longitudinal sectional view of the phase varying
device, FIG. 4(B) is a front view of a rotary drum 44 of the phase varying device,
and FIG. 4(C) is a front view of an electromagnetic clutch 42 of the phase varying
device.
[0033] The phase varying device is, as shown in FIG. 4(A), different from the aforementioned
first embodiment in the point that the electromagnetic clutch 42 is arranged in proximity
to an outer circumference of the rotary drum 44 and, as shown in FIG. 4(B), only a
vicinity of the outer circumference of the rotary drum 44 is magnetized, and is the
same as the aforementioned first embodiment in other aspects. Here, since the magnitude
of a magnetic force is greatly affected by the distance between the magnetic poles,
even when only the vicinity of the outer circumference of the rotary drum 44 is magnetized,
a sufficient magnetic force can be obtained as the magnetic poles N and S and the
electromagnets 62 are close in distance.
[0034] According to the phase varying device of the present embodiment, since the electromagnetic
clutch 42 is arranged at the outer circumferential side of the rotary drum 44, the
entire length can be made shorter than that of the aforementioned first embodiment.
In addition, since the electromagnetic clutch 42 is not arranged lateral to the rotary
drum 44, the rotary drum 44 can be reduced in diameter to reduce the moment of inertia
so as to improve the phase varying device in responsiveness. Furthermore, even when
the rotary drum 44 moves in an axial direction, the rotary drum 44 and electromagnetic
clutch 42 are always kept at an equal distance, so that highly accurate and stable
phase control becomes possible.
[0035] However, the present invention is not limited to the aforementioned embodiments.
For example, modifications can be made as follows.
[0036] The rotary drum 44 and electromagnetic clutch 42 can be modified as shown in FIG.
5 and FIG. 6. Here, FIG. 5 (A) is a front view of the rotary drum 44 of the phase
varying device, FIG. 5(B) is a sectional view along a line V-V of FIG. 5(A), FIG.
6 (A) is a front view of the electromagnetic clutch 42 of the phase varying device,
and FIG. 6(B) is a side view of the electromagnetic clutch 42. Namely, it is not necessary
to provide magnetic poles N and S formed on the rotary drum 44 alternately along the
circumferential direction of the rotary drum 44 as in the aforementioned respective
embodiments, the identical poles N (or S) may be arranged at equal intervals along
the circumferential direction of the rotary drum 44 as shown in FIG. 5, it is not
necessary for electromagnets 62 included in the electromagnetic clutch 42 to orient
their axial directions along the circumferential direction of the electromagnetic
clutch 42 as in the aforementioned respective embodiments, and these may be oriented
in a direction orthogonal to the electromagnetic clutch 42 as shown in FIG. 6.
[0037] In addition, it is not necessary to provide the magnetic poles N and S formed on
the rotary drum 44 as six poles as in the aforementioned respective embodiments, and
the poles may be of any number equal to or more than two. As a matter of course, it
is also not necessary to equalize the number of poles of the electromagnets 62 provided
in the electromagnetic clutch 42 to the number of magnetic poles N and S formed on
the rotary drum 44, and these may be arranged in any form with any number as long
as a suction force or a repulsive force is continuously given to the rotary drum 44
by the electromagnets 62.
[0038] Furthermore, in the aforementioned second embodiment where the electromagnetic clutch
42 is arranged inside the rotary drum 44, the electromagnetic clutch 42 can move in
the axial direction while keeping the distance from the rotary drum 44 fixed, however,
in order to simplify the structure, the electromagnetic clutch 42 may be fixedly fitted
to the engine case 58 so as not to be movable in the axial direction.
[0039] Furthermore, in the aforementioned respective embodiments, the electromagnetic control
means 40a can carry out either braking or acceleration of the rotary drum 44, however,
the electromagnetic control means 40a may carry out only braking. In this case, a
torsion coil spring to urge the rotary drum 44 to its initial position is indispensable.
Since such a torsion coil spring makes the engine drivable even when the electromagnetic
clutch 42 has malfunctioned, a weak torsion coil spring may be provided in the aforementioned
first to third embodiments as well.
Brief Description of the Drawings
[0040]
[FIG. 1] Views explaining a phase varying device according to a first embodiment of
the present invention.
[FIG. 2] A diagram explaining a current supplying circuit to electromagnets of the
phase varying device according to the first embodiment.
[FIG. 3] Views explaining a phase varying device according to a second embodiment
of the present invention.
[FIG. 4] Views explaining a phase varying device according to a third embodiment of
the present invention.
[FIG. 5] Views explaining a modification of a rotary drum of a phase varying device
according to the present invention .
[FIG. 6] Views explaining a modification of an electromagnetic clutch of a phase varying
device according to the present invention.
[FIG. 7] A longitudinal sectional view of a conventional phase varying device.
Description of Reference Numerals
[0041]
2 Camshaft
10 Outer casing section
12 Sprocket
20 Inner casing section
30 Intermediate member
40a Electromagnetic control means
42 Electromagnetic clutch
44 Rotary drum
62 Electromagnet
N, S Magnetic pole