Development of an End-Pivot Type Mechanical Lash Adjuster

Transcription

1 NTN TECHNICAL REVIEW No Technical Paper Development of an End-Pivot Type Mechanical Lash Adjuster Eiji MAENO Hiroshi BUNKO Katsuhisa YAMAGUCHI NTN has developed a Mechanical Lash Adjuster (MLA) that can replace conventional Hydraulic Lash Adjusters (HLA). This MLA, which applies buttress threads as the adjustment mechanism, shows excellent performance in fundamental function tests on valve-lift stability, valve-lash adjustment speed, and low-temperature characteristics. Durability tests confirmed that the MLA is capable of a 2% shorter axially design in comparison with conventional HLAs. 1. Foreword Recently, an increasing number of car models are incorporating roller rocker arm type valve systems with one of the goals being better fuel economy. However, compared with a direct type valve system a rocker arm type valve system has a more complicated structure and a greater number of wear points. Therefore, a rocker arm type valve system needs a mechanism for adjusting the valve clearance 1). Common examples of valve clearance adjustment mechanisms are a fixed type and a HLA. The fixed type valve clearance adjustment mechanism is manually adjusted with a screw and then tightened to lock the adjustment, where as the HLA is an automatic adjustment system. However, these conventional valve clearance adjustment mechanisms have drawbacks. The fixed type needs to be adjusted manually when necessary. The drawback with the HLA is that when bubbles in the engine oil enter the high-pressure chamber a decrease in rigidity and noise can occur 2). NTN has developed a unique mechanical lash adjuster (MLA) that supersedes these conventional mechanisms. This report describes the basic MLA functions and the result of their durability testing. 2. Structure Fig. 1 shows a cross-sectional view of the MLA and Fig. 2 gives a schematic view of the MLA incorporated into an automotive engine. Using buttress thread screw technology in conjunction with a return spring, the MLA is able to provide automatic adjustment of the valve clearance. On the buttress thread screw system the male thread is formed beneath the pivot member that serves as the fulcrum for the rocker arm, while the female thread is in the inner circumference on the case that houses the pivot member. By operation of a compressed coil spring the pivot member is forced upward toward the rocker arm side, while a spring seat, whose top end is spherical, is inserted between the pivot member and the compressed coil spring to decrease the running resistance on the MLA. Automotive Engineering Dept. Automotive Sales Headquarters New Product Development Dept. New Product Development R&D Center -78-

2 Development of an End-Pivot Type Mechanical Lash Adjuster MLA Pivot Case Spring seat Return spring Cap Fig. 1 Cross-section of MLA Cam Fig. 2 Installation layout of MLA Rocker arm Engine valve 3. Operating principle and functions 3. 1 Operating principle (about buttress thread screw) The static self-sustained (no occurrence of sliding rotation against the axial static load applied) condition of a screw is governed by the relation between the angles of the thread ridge (lead angle and flank angle on a cross-sectional plane square to the thread lead) and the inner-thread face friction coefficient. More specifically, if the actual friction coefficient is greater than the static self-sustaining friction coefficient s defined by tan cos, then the screw will remain at a self-sustained state; and when the former is smaller than the latter, the screw will slide 3). Because the two neighboring thread faces on a buttress thread are not symmetrical with each other, the self-sustaining coefficient ms of the buttress thread can vary depending on the orientation of the axial load acting on the buttress thread screw. In other words, by appropriately adjusting the lead angle and two flank angles, it is possible to allow the buttress thread screw to remain at a self-sustained state against an axial load working from one side and to slide and rotate by an axial load acting from the opposite side. Utilizing this direction-dependency of a buttress thread screw, the NTN MLA realizes the automatic valve clearance adjustment function. The shape of the buttress thread screw is illustrated in Fig. 3. The angles of the thread ridge are designed such that the screw slides in the projection direction for the pivot, and remains at a self-sustained state in the drive-in direction for the pivot, and that the screw does not develop wedge engagement-induced seizure against a drive-in load. The conditions required for the thread angles are summarized with the formula (1) below: tan max sec 2 ' (projecting condition) tan sec 1 (self-sustaining condition) (1) cot 1 cos (wedge angle) where, : lead angle 1 : flank angle (self-sustaining side) on a crosssectional plane A that is square to the thread lead 2 : flank angle (sliding side) on a cross-sectional plane A that is square to the thread lead : maximum friction coefficient for friction between thread faces : minimum friction coefficient for friction between thread faces Formula (2) shows the relationship between the flank angle q on the cross-sectional plane A square to the thread lead and the flank angle q on the crosssectional plane B that includes the screw axis. However, note that the buttress thread screw used on the MLA features a sufficiently small a that permits an approximation of cos 1. tan 1 tan cos (2) 1 2 A B Fig. 3 Shape of the buttress threads -79-

3 NTN TECHNICAL REVIEW No Functions In Fig. 4, typical factors that affect the valve clearance are illustrated. The lash adjuster is required to expand and/or contract in accordance with the variation in the valve clearance, which results from these factors, to maintain the valve clearance to a limited range Adjustment against enlarged valve clearance While the valve clearance increases due to factors including thermal expansion on the engine head and when the valve opens, the motion of the buttress thread screw is identical to that in the steady operation mode described in Sec On the other hand, when the valve closes, the pivot rotates in the return direction by a certain angle (an angle for slight sliding between the thread faces when the valve has opened plus an angle equivalent to a newly enlarged valve clearance), thereby the MLA expands causing the valve clearance to be maintained at an adequate level (Fig. 6). Thermal expansion on engine head Wear on valve seat Thermal expansion on valve Adjustment against decreased valve clearance A worn valve seat will lead to reduced valve clearance. Since the valve clearance further decreases in such a situation due to the backlash on the screw; consequently, when the valve closes, the pivot cannot move upward to a position where the sliding side thread faces come into contact with each other and no return rotation occurs on the pivot. Fig. 4 Factor of changing valve clearance Steady operation mode When the valve opens as the thread faces on the self-sustaining side come into contact with each other due to the input from the cam load, which results in relative sliding occurs between the thread faces because of a squeeze film and elastic deformation of the thread faces 4). When the valve closes, the pivot is lifted by the reaction force of the return spring until the sliding side thread faces come into contact with each other, thereby maintaining the MLA at a constant height (Fig. 5). Axial displacement of pivot Cam load Self-sustaining side thread face comes into contact. a When valve opens Rotation of pivot Amount of return rotation increases. Sliding side thread face comes into contact. b When valve closes Fig. 6 Motion of buttress-thread (expansion) Cam load Axial displacement of pivot Rotation of pivot Amount of return rotation = amount of sliding when valve opens Axial displacement of pivot Rotation of pivot Cam load No return rotation occurs. Pivot (male thread) Case (female thread) Self-sustaining side thread Sliding side thread face Self-sustaining side thread Sliding side thread face face comes into contact. comes into contact. face comes into contact. comes into contact. a When valve opens b When valve closes a When valve opens b When valve closes Fig. 5 Motion of buttress-thread (steady) Fig. 7 Motion of buttress-thread (contraction) -8-

4 Development of an End-Pivot Type Mechanical Lash Adjuster Because of this, the slight sliding occurring when the valve opens will accumulate, thereby the MLA will gradually contract and as a result, the valve clearance will be maintained at an appropriate level (Fig. 7). 4. Evaluation result 4. 1 Valve-lift stability Analysis method To investigate the valve-lift stability in steady operation mode, variation in the valve lift peak was measured while the engine speed was maintained at a constant level and by sweeping the engine speed (repeated variation). A picture of the engine bench test rig is shown in Fig. 8. The crankshaft of an automotive engine (15 cc) was rotated with an electric motor and the valve position was detected with eddy current type gap sensors. Since the detection range of the compact gap sensor is limited two sensors were used to measure variation in the valve lift peak. One sensor was used to measure the area around the valve lift peak and the other for measuring the area around the valve seat. The sensor configuration is illustrated in Fig. 9 and the test conditions are summarized in Table Result The valve lift peak positions are continuously plotted in Figs. 1 and 11. Fig. 1 represents a plotting obtained from an operation where the engine was run at a constant speed, while for the plot in Fig. 11, the engine speed was swept. For the test, the MLA (NTN s new product) and the HLA (conventional product) were both commonly incorporated into one automotive engine, thereby they were simultaneously analyzed. The absolute values of valve lift height are smaller with the MLA owing to the backlash on the screw in the MLA. However, the magnitude of variation in valve lift peak is the same with both the HLA and MLA. Thus, it was verified that the stability with a MLA is sufficiently high. Fig. 8 Engine bench for functional tests MLA (Cylinder_1) HLA (Cylinder_3) Oil temperature Temperature C Fig. 1 Valve lift peak (constant-rotation) Valve seating position measuring gap sensor Valve lift peak position measuring gap sensor Fig. 9 Layout of gap-sensors Table 1 Condition of valve-lift stability test MLA (Cylinder_1) 4 HLA (Cylinder_3) Crank rotation Rotation 1 min -1 Oil viscosity Oil temperature Crank speed Run duration SAE OW-2 Approx C (natural temperature increase) 1 6 min -1 constant min -1 sweeping 6 sec Fig. 11 Valve lift peak (cyclic-rotation) -81-

5 NTN TECHNICAL REVIEW No Expansion/contraction follow-up quality Analysis method After the engine is started the exhaust valve, being exposed to hot exhaust gas, undergoes thermal expansion. When the exhaust valve expands, the valve clearance will decrease. In the case of a HLA, the original valve clearance on it is. If contraction of the lash adjuster is too slow the HLA can develop compression leakage. With the MLA the backlash on the buttress thread screw functions as a valve clearance, thereby the valve expansion is compensated for and a compression leak does not occur immediately. However, expansion-contraction follow-up quality is an important characteristic for the performance of the lash adjuster. The expansioncontraction follow-up performance of the MLA was compared with that of the HLA. An example of the test bench used is shown in Fig. 12. The engine head was placed on the test bench and the camshaft was driven by an electric motor via a timing belt. The position of the valve lift was detected from beneath the valve with a laser displacement meter. The test conditions are summarized in Table 2. The displacement on the lash adjuster due to expansion/contraction was measured by inserting and removing a shim between the valve face and valve seat (as shown in Fig. 13) and then by analyzing the resultant valve behavior (seating position and peak position of the valve) Result Valve behaviors in terms of the seating position and peak position, with a.3 mm shim inserted or removed, are illustrated in Figs. 14 and Sliding on self-sustained side thread faces (backlash = ) MLA elongates, causing the lift peak to be higher a Peak position Shim inserted Shim removed Restoration of backlash Shift of seating position by the thickness of shim Variation by backlash Valve fully CLOSED b Seating position Fig. 14 Valve behavior in adjustment test MLA Fig. 12 Test bench for functional test Table 2 Condition of adjustment speed test Oil viscosity SAE OW-2 Oil temperature Approx. 4/8 C (temperature controller) Crank speed min -1 Run duration Shim Manifold 3 sec Laser displacement meter Engine valve Valve seat Valve face Fig. 13 Thim insertion diagram a Peak position Shim inserted Lift peak will become higher owing to expansion on HLA. Shim removed Leak-down Shift of seating position by the thickness of shim Valve fully CLOSED b Seating position Fig. 15 Valve behavior in adjustment test HLA -82-

6 Development of an End-Pivot Type Mechanical Lash Adjuster For both the HLA and MLA with the shim inserted, the peak position varies at almost the same time as when the valve seating position varies. This means that an increase in valve clearance resulting from the inserted shim is compensated for as the lash adjuster instantaneously expands. In other words, the expansion speed of the lash adjuster is sufficiently high relative to the thermal expansion and wear speed. After the shim is removed, the HLA gradually contracts and the seating and peak positions return to their original positions at a same speed. When the shim is removed with the MLA, the screw backlash is eliminated and the pivot is gradually driven in. Then, when the valve can be fully closed the pivot is further driven in by a distance equivalent to the screw backlash; thereby the MLA resumes its original state. The contraction speed is relatively low and this fact sometimes leads to an occurrence of compression leakage. The HLA was compared with the MLA in terms of the time needed for the lash adjuster to sink by a particular stroke (contraction time) and the result is shown in Fig. 16. Since the HLA contracts due to the oil leakage from the high-pressure chamber, its contraction time varies depending on the temperature. In contrast, the contraction time of the MLA is dependent on the running speed rather than the temperature. This is because the contraction on the MLA derives from accumulation of slight sliding on the thread faces occurring in each cycle. The follow-up speed of the MLA is slowest in the idling mode. However, this slowest speed is still sufficiently high relative to the thermal expansion speed of the valve Low temperature starting quality At lower temperatures the viscosity of oil gets higher. Due to lower temperatures the female thread face is closely situated to the male thread face, which results in an oil film more readily occurring between these thread faces (squeeze effect). If the fluid lubrication state is present between the thread faces due to this oil film (squeeze film), the friction coefficient will greatly decrease and valve lift loss to over-rotation of the screw can occur. With the MLA the thread faces are provided with both oil drain grooves and fine concavities/convexities in order to be able to dissipate the squeeze film between the thread faces in a short time and attain a mixed lubrication mode where a relatively large frictional force is obtained. Valve lift behavior in low temperature starting operation was analyzed for samples that each featured a unique thread face specification. The analysis result is presented below Analysis method The test bench for the engine head was cooled to a constant temperature of -3 C in a cryo-refrigerating chamber and the displacement in valve lift was measured. The two test pieces used (Samples A and B) each featured a unique thread face roughness and groove structure. The test conditions are summarized in Table 3. Table 3 Condition of low temp. starting test Oil viscosity SAE 1W-3 Oil temperature -3 C (constant temperature chamber) Crank speed 15 min -1 Run duration 6 sec Adjustment time sec/mm HLA (4 C) MLA (4 C) idling speed Crank rotation min -1 HLA (8 C) MLA (8 C) Fig. 16 Contraction speed of HLA and MLA Result Variations in the peak positions in the valve lift curves are plotted in Figs. 17 and 18. With Sample A the valve lift loss of approximately 1 mm occurs immediately after the engine is started. In contrast, the valve lift loss with Sample B is.1 mm or smaller. The valve lift curve of seating position obtained from Sample A is given in Fig. 19, while the seating position obtained from Sample B is illustrated in Fig. 2. In Sample A the ramp section formed on the high point of the cam is not apparent in the valve lift curve; therefore, it should be understood that the MLA sinks due to excessive sliding of the screw and the valve clearance increases to a level higher than the ramp height. In contrast, with Sample B the evidence of the presence of the ramp section is apparent, which indicates that the amount of sliding on the screw is very small. -83-

7 NTN TECHNICAL REVIEW No Valve lift mm Valve lift loss Valve lift Crank rotation Crank rotation 1 min -1 Valve lift mm Valve lift Crank rotation Crank rotation 1 min -1 Fig. 17 Valve lift peak (Sample A) Fig. 18 Valve lift peak (Sample B) Ramp height Valve lift mm Valve lift mm Fig. 19 Valve lift curve (Sample A) Fig. 2 Valve lift curve (Sample B) In conclusion, by adequately designing the surface roughness of the thread faces and groove structure it is possible to inhibit excessive sliding between thread faces even at a very low temperature ( 3 C) and attain a stable valve lift Flank pressure dependency of wear on the thread faces With the MLA the male and female thread faces are in contact with each other in a boundary lubrication or mixed lubrication state; therefore reducing wear on the thread faces poses an engineering challenge. In an attempt to address this issue an automotive engine was subjected to a durability test in order to determine the allowance for thread face flank pressure. From the durability test the wear on the female thread face of the case member was measured Test method As shown in Fig. 8, the crankshaft of an automotive engine was driven with an electric motor. The thread faces of each specimen were preconditioned such that excessive sliding of the screw did not occur in the low temperature starting test. In addition, by varying the area of thread faces the flank pressures were sorted into several groups. The test conditions applied are summarized in Table 4. Oil viscosity Oil temperature Crank speed Table 4 Condition of the endurance test SAE W-2 Approx. 11 C (natural temperature increase) Engine maximum output speed Result The interrelation between the maximum flank pressure on the thread faces and the wear on the female thread face on the case member is illustrated in Fig. 21. Each maximum thread face flank pressure was calculated based on the maximum value of the load being an input to the MLA within one rotation of the camshaft. According to this result, it is possible to determine the minimum necessary mesh height with -84-

8 Development of an End-Pivot Type Mechanical Lash Adjuster Wear of thread face of female screw Upper limit of standard the threaded section and obtain a MLA design that is optimized for an automotive engine application. If NTN s MLA is applied to an automotive engine, for example a 15 cc class engine, the axial dimension of the resultant package can be approximately 2% smaller compared with a package comprising of an HLA with the same outside diameter as our MLA. 5. Conclusion Criteria Maximum pressure of thread face Fig. 21 Wear on the threaded flank of female screw with respect to maximum flank pressure We have evaluated the basic functions and durability of an automatic valve clearance adjuster (mechanical lash adjuster/mla) that incorporates a buttress thread screw and obtained the following findings: 1) When the engine is running at a constant speed (6 min -1 ) or when the engine speed is swept (6-6 min -1 ), the variation in valve lift peak with the MLA is comparable with that of the currently mass-produced hydraulic lash adjuster (HLA). Thus, we have verified that the MLA has attained sufficiently high stability. 2) The contraction speed of the MLA is governed by the engine speed and is least dependent on the temperature. The contraction speed is lowest when the engine is idling; nevertheless, the lowest contraction speed is still sufficiently high compared with the thermal expansion speed of the valve. 3) It has been verified that by adequately designing the quality of thread faces the valve lift loss at -3 C is limited to.1 mm or smaller. 4) Based on the relation between the wear on the thread faces and the flank pressure on thread faces, the minimum necessary mesh height for the threaded faces is determined. With the mesh height known it is now possible to optimally design the MLA that best suits the intended automotive engine. For example, if our MLA is adopted for a 15 ccclass engine the axial length needed is approximately 2% shorter compared with the HLA of the same outside diameter. References 1) Kimihiko Todo, Yuji Yoshihara: Gasoline Engine: Roller Arm, Journal of Society of Automotive Engineers of Japan, No.59 p.29 (25-2) 2) Noriyuki Miyamura, Syuji Nagano: Hydraulic Lash Adjuster, Journal of Society of Automotive Engineers of Japan, No.38 p.111 (1984-9) 3) Akira Yamamoto: Principles and Design of Screw Fastening, Yokendo, p.3 (197) 4) Bunko et al.: Fundamental analysis of the dynamic behavior of buttress-threaded screws, Japan Society of Mechanical Engineers, 25 Annual Conference Proceedings (4), p.147 (25) Photos of authors Eiji MAENO Automotive Engineering Dept. Automotive Sales Headquarters Hiroshi BUNKO New Product Development Dept. New Product Development R&D Center Katsuhisa YAMAGUCHI New Product Development Dept. New Product Development R&D Center -85-