U.S. patent application number 16/866038 was filed with the patent office on 2021-04-01 for variable travel valve apparatus for an internal combustion engine.
This patent application is currently assigned to JP Scope, Inc.. The applicant listed for this patent is JP Scope, Inc.. Invention is credited to Caleb ALVARADO, William ANDERSON, Guy Robert BABBITT, Stephen John CHARLTON, Drew COHEN, Nicholas Paul ECHTER, David EVANS, Clayton JACOBS, Jay MCFARLANE, Daniel S. PEDERSEN, Charles PRICE, Christopher Wayne TURNER, Kristina WEYER-GEIGEL.
Application Number | 20210095614 16/866038 |
Document ID | / |
Family ID | 1000005273698 |
Filed Date | 2021-04-01 |
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United States Patent
Application |
20210095614 |
Kind Code |
A1 |
PRICE; Charles ; et
al. |
April 1, 2021 |
VARIABLE TRAVEL VALVE APPARATUS FOR AN INTERNAL COMBUSTION
ENGINE
Abstract
An apparatus includes a valve and an actuator. The valve has a
portion movably disposed within a valve pocket defined by a
cylinder head of an engine. The valve is configured to move
relative to the cylinder head a distance between a closed position
and an opened position. The portion of the valve defines a flow
opening that is in fluid communication with a cylinder of an engine
when the valve is in the opened position. The actuator is
configured to selectively vary the distance between the closed
position and the opened position.
Inventors: |
PRICE; Charles; (Mt. Juliet,
TN) ; MCFARLANE; Jay; (Mt. Juliet, TN) ;
CHARLTON; Stephen John; (Rancho Santa Fe, CA) ;
ANDERSON; William; (Cameron Park, CA) ; EVANS;
David; (Nederland, CO) ; BABBITT; Guy Robert;
(Fort Collins, CO) ; TURNER; Christopher Wayne;
(Windsor, CO) ; PEDERSEN; Daniel S.; (Fort
Collins, CO) ; JACOBS; Clayton; (Loveland, CO)
; COHEN; Drew; (Fort Collins, CO) ; ECHTER;
Nicholas Paul; (Fort Collins, CO) ; WEYER-GEIGEL;
Kristina; (Yakima, WA) ; ALVARADO; Caleb;
(Fort Collins, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JP Scope, Inc. |
Mt. Juliet |
TN |
US |
|
|
Assignee: |
JP Scope, Inc.
Mt. Juliet
TN
|
Family ID: |
1000005273698 |
Appl. No.: |
16/866038 |
Filed: |
May 4, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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16296857 |
Mar 8, 2019 |
10690085 |
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16866038 |
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PCT/US17/51016 |
Sep 11, 2017 |
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16296857 |
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62385804 |
Sep 9, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F02F 1/24 20130101; F01L
2009/2105 20210101; F01L 9/20 20210101; F02F 2001/244 20130101 |
International
Class: |
F02F 1/24 20060101
F02F001/24; F01L 9/04 20060101 F01L009/04 |
Claims
1-20. (canceled)
21. A method, comprising: moving a valve member in a first
direction within a valve pocket defined by a cylinder head from a
first configuration to a second configuration such that a gas
manifold is in fluid communication with a cylinder via a plurality
of valve passages defined by the valve member; moving the valve
member in a second direction opposite the first direction within
the valve pocket from the second configuration to a third
configuration such that the gas manifold is fluidically isolated
from the cylinder; and releasing the valve member such that the
valve member moves to the first configuration.
22. The method of claim 21, wherein the moving the valve member in
the first direction includes pushing the valve member.
23. The method of claim 21, wherein the moving the valve member in
the second direction includes pulling the valve member.
24. The method of claim 21, wherein the moving the valve member in
the second direction includes pushing the valve member.
25. The method of claim 21, wherein the gas manifold is in fluid
communication with the cylinder via the plurality of valve flow
passages in the first configuration.
26. The method of claim 21, wherein the plurality of valve flow
passages are at least partially obstructed by a portion of the
cylinder head disposed between the valve member and the cylinder in
the first configuration.
27. The method of claim 21, wherein the valve member is a first
valve member, the valve pocket is a first valve pocket, and the gas
manifold is a first gas manifold, the method further comprising:
moving a second valve member in a first direction within a second
valve pocket defined by the cylinder head from a first
configuration to a second configuration such that a second gas
manifold is fluidically isolated from the cylinder; moving the
second valve member in a second direction opposite the first
direction within the second valve pocket from the second
configuration to a third configuration such that the second gas
manifold is in fluidic communication with the cylinder; and
releasing the valve member such that the valve member moves to the
first configuration.
28. The method of claim 27, wherein the moving the second valve
member in the first direction includes pulling the valve
member.
29. The method of claim 27, wherein the moving the second valve
member in the first direction includes pushing the valve
member.
30. The method of claim 27, wherein the moving the second valve
member in the second direction includes pushing the valve
member.
31. A method, comprising: applying a first current to a first
electromagnetic coil of an actuation assembly such that an armature
is drawn toward the first electromagnetic coil, the armature being
coupled to a valve member such that the movement of the armature
causes the valve member to move within a valve pocket defined by a
cylinder head from a neutral configuration to an open
configuration, the valve member defining a plurality of valve flow
passages, a gas manifold being in fluidic communication with a
cylinder via the plurality of valve flow passages in the open
configuration, ceasing the application of the first current to the
first electromagnetic coil such that the valve member moves to the
neutral configuration, and applying a second current to a second
electromagnetic coil of an actuation assembly such that the valve
member moves to a closed configuration, the gas manifold being
fluidically isolated from the cylinder in the closed
configuration.
32. The method of claim 31, further comprising: ceasing the
application of the second current to the second electromagnetic
coil such that the valve member moves to the neutral
configuration.
33. The method of claim 31, wherein, after the ceasing of the
application of the first current, the valve member moves to the
neutral configuration via a force applied by a first biasing
member.
34. The method of claim 31, wherein, after the ceasing of the
application of the second current, the valve member moves to the
neutral configuration via a force applied by a second biasing
member.
35. The method of claim 31, wherein, when in the neutral
configuration, the gas manifold is in fluidic communication with
the cylinder and the plurality of valve flow passages are at least
partially obstructed by a portion of the cylinder head disposed
between the valve member and the cylinder.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 16/296,857, filed Mar. 8, 2019, entitled
"Variable Travel Valve Apparatus for an Internal Combustion
Engine," which is a continuation of PCT Application No.
PCT/US2017/051016, filed Sep. 11, 2017, entitled "Variable Travel
Valve Apparatus for an Internal Combustion Engine," which claims
priority to and the benefit of U.S. Provisional Application No.
62/385,804, filed Sep. 9, 2016, entitled "Variable Travel Valve
Apparatus for an Internal Combustion Engine," the entire contents
of each of which are hereby expressly incorporated by reference for
all purposes.
BACKGROUND
[0002] The embodiments described herein relate to an apparatus for
controlling gas exchange processes in a fluid processing machine,
and more particularly to a valve and cylinder head assembly for an
internal combustion engine.
[0003] Many fluid processing machines, such as, for example,
internal combustion engines, compressors, and the like, require
accurate and efficient gas exchange processes to ensure optimal
performance. For example, during the intake stroke of an internal
combustion engine, a predetermined amount of air and fuel must be
supplied to the combustion chamber at a predetermined time in the
operating cycle of the engine. The combustion chamber then must be
sealed during the combustion event to prevent inefficient operation
and/or damage to various components in the engine. During the
exhaust stroke, the burned gases in the combustion chamber must be
efficiently evacuated from the combustion chamber.
[0004] Some known internal combustion engines use poppet valves to
control the flow of gas into and out of the combustion chamber.
Known poppet valves are reciprocating valves that include an
elongated stem and a broadened sealing head. In use, known poppet
valves open inwardly towards the combustion chamber such that the
sealing head is spaced apart from a valve seat, thereby creating a
flow path into or out of the combustion chamber when the valve is
in the opened position. The sealing head can include an angled
surface configured to contact a corresponding surface on the valve
seat when the valve is in the closed position to effectively seal
the combustion chamber.
[0005] The enlarged sealing head of known poppet valves, however,
obstructs the flow path of the gas coming into or leaving the
combustion cylinder, which can result in inefficiencies in the gas
exchange process. Moreover, the enlarged sealing head can also
produce vortices and other undesirable turbulence within the
incoming air, which can negatively impact the combustion event. To
minimize such effects, some known poppet valves are configured to
travel a relatively large distance between the closed position and
the opened position. Increasing the valve lift, however, results in
higher parasitic losses, greater wear on the valve train, greater
chance of valve-to-piston contact during engine operation, and the
like.
[0006] Because the sealing head of known poppet valves extends into
the combustion chamber, they are exposed to the extreme pressures
and temperatures of engine combustion, which increases the
likelihood that the valves will fail or leak. Exposure to
combustion conditions can cause, for example, greater thermal
expansion, detrimental carbon deposit build-up and the like.
Moreover, such an arrangement is not conducive to servicing and/or
replacing valves. In many instances, for example, the cylinder head
must be removed to service or replace the valves.
[0007] To reduce the likelihood of leakage, known poppet valves are
biased in the closed position using relatively stiff springs. Thus,
known poppet valves are often actuated using a camshaft to produce
the high forces necessary to open the valve. Known camshaft-based
actuation systems, however, have limited flexibility to change the
valve travel (or lift), timing and/or duration of the valve event
as a function of engine operating conditions. For example, although
some known camshaft-based actuation systems can change the valve
opening or duration, such changes are limited because the valve
events are dependent on the rotational position of the camshaft
and/or the engine crankshaft. Accordingly, the valve events (i.e.,
the timing, duration and/or travel) are not optimized for each
engine operating condition (e.g., low idle, high speed, full load,
etc.), but are rather selected as a compromise that provides the
desired overall performance.
[0008] Some known poppet valves are actuated using electronic
actuators or hydraulics. Solenoid-based actuation systems, however,
often require multiple springs and/or solenoids to overcome the
force of the biasing spring. Moreover, solenoid-based actuation
systems require relatively high power to actuate the valves against
the force of the biasing spring. Hydraulic-based systems require
parts with very close tolerances and require a hydraulic power
supply.
[0009] Thus, a need exists for an improved valve actuation system
for an internal combustion engine and like systems and devices.
SUMMARY
[0010] Gas exchange valves and methods are described herein. In
some embodiments, an apparatus includes a valve and an actuator.
The valve has a portion movably disposed within a valve pocket
defined by a cylinder head of an engine. The valve is configured to
move relative to the cylinder head a distance between an
equilibrium position, a closed position and an opened position. The
portion of the valve defines a flow opening that is in fluid
communication with a cylinder of an engine when the valve is in the
opened position. The actuator is configured to selectively vary the
distance between the closed position and the opened position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross-sectional view of a portion of an engine
including a cylinder head assembly according to an embodiment.
[0012] FIG. 2 is a perspective view of a solenoid assembly
associated with the cylinder head assembly illustrated in FIG.
1.
[0013] FIG. 3 is an exploded view solenoid assembly in FIG. 5.
[0014] FIG. 4 is a perspective view of a cylinder head assembly,
according to an embodiment.
[0015] FIG. 5 is a perspective view of an intake valve member,
according to an embodiment.
[0016] FIG. 6 is a perspective view of an exhaust valve member,
according to an embodiment.
[0017] FIG. 7 is a partially exploded view of the cylinder head
assembly of FIG. 4 in a first configuration.
[0018] FIG. 8 is a partially exploded view of the cylinder head
assembly of FIG. 4 in a second configuration.
[0019] FIG. 9 is a perspective view of a portion of an engine
including a cylinder head assembly, according to an embodiment.
[0020] FIG. 10 is a perspective view of a cylinder head assembly,
according to an embodiment.
[0021] FIG. 11 is a perspective view of a cylinder head assembly,
according to an embodiment.
[0022] FIG. 12 is a perspective view of a cylinder head assembly,
according to an embodiment.
[0023] FIGS. 13A and 13B are a bottom view and a side view,
respectively, of an exhaust valve and an intake valve, according to
an embodiment.
[0024] FIG. 14 is a schematic illustration of a valve system,
according to an embodiment.
[0025] FIG. 15 is a perspective view of a cylinder head assembly,
according to an embodiment.
[0026] FIG. 16 is a schematic illustration of a valve system,
according to an embodiment.
[0027] FIG. 17 is a schematic illustration of a valve system,
according to an embodiment.
[0028] FIG. 18 is a schematic illustration of a valve system,
according to an embodiment.
[0029] FIG. 19 is a schematic illustration of a valve system,
according to an embodiment.
[0030] FIG. 20 is a schematic illustration of a valve system,
according to an embodiment.
[0031] FIG. 21 is a schematic illustration of a valve system,
according to an embodiment.
[0032] FIG. 22 is a schematic illustration of a valve system,
according to an embodiment.
[0033] FIG. 23 is a schematic illustration of a valve actuator,
according to an embodiment.
[0034] FIG. 24 is a schematic illustration of a valve actuator,
according to an embodiment.
[0035] FIG. 25 is a schematic illustration of a valve actuator,
according to an embodiment.
[0036] FIG. 26 is a perspective view of an actuator backiron,
according to an embodiment.
[0037] FIG. 27 is a schematic illustration of a portion of a
backiron, according to an embodiment.
[0038] FIG. 28 is a cross-sectional view of a portion of an engine
including a cylinder head assembly, according to an embodiment.
[0039] FIGS. 29A and 29B are a first perspective view and a second
perspective view, respectively, of a cylinder head, according to an
embodiment.
[0040] FIGS. 29C and 29D are a top perspective view and a bottom
perspective view, respectively, of a bottom layer of the cylinder
head of FIG. 29A.
[0041] FIGS. 29E and 29F are a top perspective view and a bottom
perspective view, respectively, of a middle layer of the cylinder
head of FIG. 29A.
[0042] FIGS. 30A-30C are various views of an intake valve member,
according to an embodiment.
[0043] FIGS. 31A-31C are various views of an intake valve member,
according to an embodiment.
[0044] FIG. 32 is a partially exploded perspective view of a
cylinder head assembly, according to an embodiment.
[0045] FIG. 33 is a perspective view of a cylinder head assembly,
according to an embodiment.
[0046] FIG. 34 is a cross-sectional view of an engine, according to
an embodiment.
[0047] FIGS. 35A and 35B are schematic cross-sectional
illustrations of a valve bridge and a cylinder bridge in a first
configuration and a second configuration, respectively, according
to an embodiment.
[0048] FIG. 36 is a schematic cross-sectional exemplary
illustrations of the forces applied to a valve member in a closed
configuration relative to a cylinder bridge, according to an
embodiment.
[0049] FIGS. 37A and 37B are exemplary graphs of the forces and
pressure applied to a valve member at various crank angles,
according to an embodiment.
[0050] FIGS. 38A and 38B are a perspective view and a partially
exploded view, respectively, of an assembly, according to an
embodiment.
[0051] FIG. 39A is a perspective view of the top of a piston,
according to an embodiment.
[0052] FIG. 39B is a perspective view of the top of a piston,
according to an embodiment.
[0053] FIG. 39C is a perspective view of the top of a piston,
according to an embodiment.
[0054] FIGS. 40A and 40B are graphical illustrations of various
valve actuation cycles through various crank angles, according to
various embodiments.
[0055] FIG. 41A is an illustrative model of velocity vectors of
fluid traveling through an engine, according to an embodiment.
[0056] FIG. 41B is close up view of a portion of FIG. 41A.
[0057] FIG. 42 is a schematic illustration of a system, according
to an embodiment.
[0058] FIG. 43 is a schematic illustration of a system, according
to an embodiment.
[0059] FIG. 44A is a cross-sectional illustration of a flow
passage, according to an embodiment.
[0060] FIG. 44B is a cross-sectional illustration of a flow
passage, according to an embodiment.
[0061] FIG. 45 is a method of operating a cylinder head assembly,
according to an embodiment.
[0062] FIG. 46 is a method of operating a cylinder head assembly,
according to an embodiment.
[0063] FIG. 47 is a perspective view of a valve member, according
to an embodiment.
[0064] FIG. 48 is a cross-sectional illustration of a cylinder head
and a valve member, according to an embodiment.
DETAILED DESCRIPTION
[0065] In some embodiments, an apparatus includes a valve and an
actuator. The valve has a portion movably disposed within a valve
pocket defined by a cylinder head of an engine. The valve is
configured to move relative to the cylinder head a distance between
an equilibrium position, a closed position and an opened position.
The portion of the valve defines a flow opening that is in fluid
communication with a cylinder of an engine when the valve is in the
opened position. The actuator is configured to selectively vary the
distance between the closed position and the opened position.
[0066] In some embodiments, an apparatus includes a cylinder head
and a valve member. The cylinder head can have an interior surface
defining a valve pocket. The cylinder head can be configured to be
coupled to a cylinder and a gas manifold. The valve member can have
a portion defining a plurality of valve flow passages. The valve
member can be configured to be disposable within the valve pocket
such that the valve member is movable within the valve pocket along
a longitudinal axis of the valve member. The apparatus can have a
first configuration, a second configuration, and a third
configuration. In the first configuration, each valve flow passage
from the plurality of valve flow passages can be in fluid
communication with the cylinder and the gas manifold. In the second
configuration, each valve flow passage from the plurality of valve
flow passages can be fluidically isolated from the cylinder. In the
third configuration, the valve member can be disposed in a position
different from the first configuration and the second
configuration. The valve member can be biased toward the third
configuration.
[0067] In some embodiments, an apparatus includes a cylinder head
and a valve member. The cylinder head can have an interior surface
defining a valve pocket. The cylinder head can be configured to be
coupled to a cylinder and a gas manifold. A portion of the valve
pocket can including sealing portions which define a plurality of
cylinder flow passages. The valve member can have a portion
defining a plurality of valve flow passages, the valve member
configured to be disposable within the valve pocket such that the
valve member is movable within the valve pocket along a
longitudinal axis of the valve member. The apparatus can have a
first configuration, a second configuration, and a third
configuration. In the first configuration, each valve flow passage
from the plurality of valve flow passages can be in fluid
communication with the cylinder and the gas manifold, the plurality
of valve flow passages in fluid communication with the cylinder via
the plurality of cylinder flow passages. In the second
configuration, each valve flow passage from the plurality of valve
flow passages can be fluidically isolated from the cylinder via the
sealing portions of the valve pocket. In the third configuration,
an opening to each of the plurality of valve flow passages is at
least partially obstructed by the sealing portions of the valve
pocket such that each valve flow passage from the plurality of
valve flow passages is in fluid communication with the cylinder and
the gas manifold. The valve member can be biased toward the third
configuration.
[0068] In some embodiments, a method includes moving a valve member
in a first direction within a valve pocket defined by a cylinder
head from a first configuration to a second configuration such that
a gas manifold is in fluid communication with a cylinder via a
plurality of valve passages defined by the valve member. Next, the
valve member can be moved in a second direction opposite the first
direction within the valve pocket from the second configuration to
a third configuration such that the gas manifold is fluidically
isolated from the cylinder. The valve member can be released such
that the valve member moves to the first configuration.
[0069] In some embodiments, a method includes applying a first
current to a first electromagnetic coil of an actuation assembly
such that an armature is drawn toward the first electromagnetic
coil. The armature can be coupled to a valve member such that the
movement of the armature causes the valve member to move within a
valve pocket defined by a cylinder head from a neutral
configuration to an open configuration. The valve member can define
a plurality of valve flow passages. A gas manifold can be in
fluidic communication with a cylinder via the plurality of valve
flow passages in the open configuration. The application of the
first current to the first electromagnetic coil can be ceased such
that the valve member moves to the neutral configuration. A second
current can then be applied to a second electromagnetic coil of an
actuation assembly such that the valve member moves to a closed
configuration, the gas manifold being fluidically isolated from the
cylinder in the closed configuration.
[0070] FIG. 1 is a cross-sectional front view of a portion of an
engine 100 including a cylinder head assembly capable of performing
fully variable valve actuation, according to an embodiment. The
engine 100 includes an engine block 102 and a cylinder head
assembly 130 coupled to the engine block 102. The engine block 102
defines or includes a cylinder 103 having a longitudinal axis Lc. A
piston (not shown) can be disposed within the cylinder 103 such
that it can reciprocate along the longitudinal axis Lc of the
cylinder 103. The piston can be coupled by a connecting rod (not
shown) to a crankshaft (not shown) having an offset throw (not
shown) such that as the piston reciprocates within the cylinder
103, the crankshaft is rotated about its longitudinal axis (not
shown). In this manner, the reciprocating motion of the piston can
be converted into a rotational motion.
[0071] A first surface 135 of the cylinder head assembly 130 can be
coupled to the engine block 102 such that a portion of the first
surface 135 covers the upper portion of the cylinder 103 thereby
forming a combustion chamber 109. Although the portion of the first
surface 135 covering the cylinder 103 is shown as being flat (and,
in some embodiments, lies parallel to the top surface of a piston
within the combustion chamber 109), in some embodiments, because
the cylinder head assembly 130 does not include valves that
protrude into the combustion chamber, the surface of the cylinder
head assembly forming part of the combustion chamber can have any
suitable geometric design. For example, in some embodiments, the
surface of the cylinder head assembly forming part of the
combustion chamber can be curved and angularly offset from the top
surface of the piston. In other embodiments, the surface of the
cylinder head assembly forming part of the combustion chamber can
be curved to form a hemispherical combustion chamber, a pent-roof
combustion chamber or the like.
[0072] A gas manifold 110 defining an interior area or port 112 is
coupled to a second surface 136 of the cylinder head assembly 130
such that the interior area 112 of the gas manifold 110 is in fluid
communication with a valve pocket 138 via an opening in the second
surface 136. As described in detail herein, this arrangement allows
a gas, such as, for example air or combustion by-products, to be
transported into or out of the cylinder 103 via the cylinder head
assembly 130 and the gas manifold 110. Although shown as including
a single gas manifold 110, in some embodiments, an engine can
include two or more gas manifolds. For example, in some embodiments
an engine can include an intake manifold configured to supply air
and/or an air-fuel mixture to the cylinder head and an exhaust
manifold configured to transport exhaust gases away from the
cylinder head.
[0073] Moreover, as shown, in some embodiments the first surface
135 of the cylinder head assembly 130 can be opposite the second
surface 136. In some embodiments, the cylinder head assembly 130 is
arranged such that the flow of gas into and/or out of the cylinder
103 can occur along a substantially straight line. In such an
arrangement, a fuel injector (not shown) can be disposed in an
intake manifold (not shown) directly above cylinder flow passages
148 (described below). In this manner, the injected fuel can be
conveyed into the cylinder 103 without being subjected to a series
of bends. Eliminating bends along the fuel path can reduce fuel
impingement and/or wall wetting, thereby leading to more efficient
engine performance, such as, for example, improved transient
response.
[0074] The cylinder head assembly 130 includes a cylinder head 132
and a valve member 160. The cylinder head 132 includes a cylinder
bridge portion 194 (also referred to as a cylinder bridge). The
cylinder bridge 194 of the cylinder head 132 has an interior
surface 134 that defines the bottom of a valve pocket 138 having a
longitudinal axis Lp. The cylinder bridge 194 also includes a
bottom surface that can define the top of the combustion chamber
109. For example, as shown in FIG. 1, the bottom surface of the
cylinder bridge is the same surface as first surface 135. The
cylinder bridge 194 also defines eight cylinder flow passages 148.
Each of the cylinder flow passages 148 is adjacent the first
surface 135 of the cylinder head 132 and is in fluid communication
with the cylinder 103. Additionally, each of the cylinder flow
passages 148 can be in fluid communication with the valve pocket
138 in a condition where the cylinder flow passages 148 are not
obstructed by the valve member 160. The cylinder bridge 194 also
includes a number of sealing portions 155 which can define the
cylinder flow passages 148.
[0075] The valve member 160 has a flow passage portion 162 (also
referred to as a valve bridge or valve bridge portion), a first
stem portion 176, and a second stem portion 177. The valve member
160 can have a tapered shape (e.g., a partially tapered outer wall
portion), as shown in FIG. 1. The first stem portion 176 is coupled
to an end of the flow passage portion 162 of the valve member 160
and is configured to engage a first plug 178. The first plug 178 is
configured to engage with an actuator assembly 180 (also referred
to herein as a solenoid assembly) (shown in perspective view in
FIG. 2 and in exploded view in FIG. 3). The second stem portion 177
is coupled to an end of the flow passage portion 162 opposite from
the first stem portion 176 and is configured to engage a second
plug 179. The second plug 179 is configured to engage with a spring
assembly 120 (also referred to herein as a return assembly).
[0076] The solenoid assembly 180 includes an armature 181, a
connecting rod 183, a force application member 184, and a spring
185. The solenoid assembly 180 also includes an electromagnetic
open coil 182 and an electromagnetic close coil 186. The force
application member 184 is configured to engage with the first plug
178 such that a force applied to the first plug 178 can cause
movement of the valve member 160. The engagement between the force
application member 184 and the first plug 178 can be abutting
contact. Said another way, the force application member 184 and the
first plug 178 can include no articulated joint or interlocking
features. In other embodiments, the engagement between the force
application member 184 and the first plug 178 and/or the valve
member 160 can include interlocking features.
[0077] The spring assembly 120 includes a spring 122 and a spring
force application member 121. The spring 122 can be configured to
elastically deform and be biased toward an expanded configuration.
The spring force application member 121 can be formed of an
inelastic, stiff material. For example, the spring force
application member 121 can be formed of steel and/or titanium. The
spring force application member 121 is configured to engage with
the second plug 179 such that a force applied to the second plug
179 by the spring assembly 120 (e.g., due to being biased toward an
expanded configuration) can cause movement of the valve member 160.
The engagement between the spring force application member 121 and
the second plug 179 can be abutting contact. Said another way, the
spring force application member 121 and the second plug 179 can
include no articulated joint or interlocking features. In other
embodiments, the engagement between the spring force application
member 121 and the second plug 179 and/or the valve member 160 can
include interlocking features.
[0078] The flow passage portion 162 of the valve member 160 defines
eight flow passages 168 therethrough. The flow passage portion 162
includes a number of sealing portions 172, each of which is
disposed adjacent one of the flow passages 168 and disposed on
and/or includes a bottom surface 163 of the flow passage portion
162. In some embodiments, the sealing portions 172 define the
openings to the flow passages 168 on the bottom surface 163 of the
flow passage portion 162. The valve member 160 is disposed within
the valve pocket 138 such that the flow passage portion 162 of the
valve member 160 can be moved along a longitudinal axis Lv of the
valve member 160 within the valve pocket 138. For example, the
solenoid assembly 180 can be configured to apply a force to the
first plug 178 such that the valve member 160 shifts in the
direction of arrow A. Similarly, the solenoid assembly 180 can be
configured to apply a second force to the force application member
184 such that the force application member shifts in the direction
of arrow B, causing the valve member 160 to also shift in the
direction of arrow B under the force of the spring assembly 120.
Said another way, the spring assembly 120 can be configured to
apply a force to the second plug 179 such that the valve member 160
shifts in the direction of arrow B. In some embodiments, the
solenoid assembly 180 can be engaged with the valve member via an
interlocking element, rather than just being disposed in abutting
contact, such that the solenoid assembly 180 is configured to apply
a second force to the first plug 178 such that the valve member 160
shifts in the direction of arrow B.
[0079] The spring 122 and the spring 185 can both be biased toward
the valve member 160 (i.e., the spring 122 and the spring 185 are
both center-biased). Thus, in a configuration in which no current
is applied to the armature 181 of the solenoid assembly 180 (i.e.,
no current is applied to the open coil 182 or the close coil 186),
the spring forces applied to the valve member 160 by the spring 185
and the spring 122 will cause the valve member 160 to be
center-biased in a neutral position such that the valve member 160
is disposed in a centered or substantially centered position
relative to the cylinder head 132 and the valve member 160 is
partially open. In other words, the flow passages 168 can be
partially aligned with the flow passages 148 such that at least a
portion of the cylinder-side opening to each flow passage 168 is in
fluid communication with a flow passage 148 and a portion of the
cylinder-side opening to each flow passage 168 is obstructed,
blocked, or closed by a sealing portion 155. In some embodiments,
the spring 122 and the spring 185 can be biased toward the valve
member 160 such that in the absence of a current applied to the
coils 182, 186 of the solenoid assembly 180, the valve member 160
is disposed halfway between the location of the valve member 160 in
an open position (e.g., the position of the valve member 160 when a
current is applied to the open coil 182) and the location of the
valve member 160 in a closed position (e.g., the position of the
valve member 160 when a current is applied to the close coil
186).
[0080] In some embodiments, the spring 122 and the spring 185 can
be biased toward the valve member 160 such that in the absence of a
current applied to the coils 182, 186 of the solenoid assembly 180,
the valve member 160 is disposed partway along the translation path
between the location of the valve member 160 in an open position
(e.g., the position of the valve member 160 when a current is
applied to the open coil 182) and the location of the valve member
160 in a closed position (e.g., the position of the valve member
160 when a current is applied to the close coil 186). In some
embodiments, the valve member 160 can be positioned closer to the
open position, closer to the closed position, or at the midway
point. In some embodiments, one or more flow passages 168 of the
valve member 160 can be partially obstructed by a sealing portion
172 of the flow passage portion 162. In some embodiments, the
offset in central axes between the flow passages 168 and the
sealing portions 172 when the valve member 160 is in the neutral
position can result in the openings of the flow passages 168 in the
bottom surface 163 of the flow passage portion 162 being about 50%
obstructed, more than 50% obstructed, or less than 50%
obstructed.
[0081] As shown in the configuration of FIG. 1, when the solenoid
assembly 180 is actuated such that current is delivered to the open
coil 182, the armature 181 can be configured to shift toward the
open coil 182, allowing the connecting rod 183 and the force
application member 184 to move into force-applying contact with the
first plug 178 as a result of the force from spring 185. Thus, the
valve member 160 can be pushed by the force application member 184
in the direction of arrow A against the force applied by spring 122
such that the flow passages 168 are in alignment with the flow
passages 148 (as shown by the configuration illustrated in FIG. 1).
When the flow passages 168 are in alignment with the flow passages
148, each of the flow passages 168 can be in fluid communication
with one of the cylinder flow passages 148. In this manner, the gas
manifold 110 is in fluid communication with the cylinder 103 via
the flow passages 168, 148. When the current is removed from the
open coil 182, a return force applied by the spring 122 in
combination with the spring force application member 121 can push
the valve member 160 in the direction of arrow B such that the
valve member 160 returns to the equilibrium position.
[0082] When the solenoid assembly 180 is actuated such that current
is delivered to the close coil 186, the armature 181 can be
configured to shift toward the close coil 186, moving the
connecting rod 183 and the force application member 184 in the
direction of arrow B against the force of spring 185 and reducing
the force applied on the first plug 178 by the force application
member 184. Due to the reduced force applied on the first plug 178
by the force application member 184, the valve member 160 can be
pushed by the spring assembly 120 in the direction of arrow B such
that the flow passages 168 are out of alignment with the flow
passages 148. In other words, the valve member 160 can be disposed
such that the flow passages 168 are sealed from the combustion
chamber 109 by the sealing portions 172. Moreover, when each flow
passage 168 is offset from the corresponding cylinder flow passage
148, each flow passage 168 is fluidically isolated from the
cylinder flow passages 148. In this manner, the cylinder 103 is
fluidically isolated from the gas manifold 110. When the current is
removed from the close coil 186, a return force applied by the
spring 185 in combination with the force application member 184 can
push the valve member 160 in the direction of arrow A against the
force of the spring assembly 120 such that the valve member 160
returns to the equilibrium position. In some embodiments, rather
than the valve member 160 being moved to the fully closed position
in the direction of arrow B via the force of the spring 122 being
stronger than the force of the spring 185, the solenoid assembly
180 can be coupled to the valve member 160 such that the movement
of the armature 181 can pull the valve member 160 against the force
of the spring 185 and into the closed or partially closed
position.
[0083] In some embodiments, the solenoid assembly 180 can be
actuated to apply a "boost pulse" to the valve member 160. For
example, a current can be delivered to one of the open coil 182 or
the close coil 186 to assist movement of the valve (e.g., to
overcome friction forces). In some embodiments, the solenoid
assembly 180 can be actuated to apply sufficient current to the
open coil 182 and/or the close coil 186 to precisely control the
location of the armature 181 between the open coil 182 and the
close coil 186 such that the position of the valve member 160 is
precisely controlled relative to the cylinder bridge 194. Thus, in
some embodiments, the valve member 160 can be positioned by the
cylinder head assembly 130 at an infinite number of positions
relative to the cylinder bridge 194 corresponding to an infinite
number of flow areas and volumetric flow rates through the valve
member 160.
[0084] In some embodiments, the force needed for movement (e.g.,
reciprocating or translating) of the valve member 160 can be
provided substantially by the spring 122 and/or the spring 185,
with the solenoid assembly 180 applying only boost pulses to the
force application member 184 when needed to maintain the movement
of the valve member 160 as desired. The boost pulses can be used to
accelerate or decelerate the valve member 160. In some embodiments,
the solenoid assembly 180 can be actuated to hold the valve member
160 in a particular position (e.g., open, close, or partially open)
relative to the cylinder bridge 194 for a desired period of time.
In some embodiments, when the solenoid assembly 180 ceases applying
current to the coils 182 and 186, the valve member 180 can be
configured to be reciprocated or oscillated by the springs 120 and
185 (due to springs 120 and 185 being biased toward an expanded
configuration) until the valve member 180 has returned to a natural
center-biased position between the return assembly 120 and the
actuator assembly 180. For example, each of the springs 120 and 185
can act both as an actuator and a damper as the valve member 180
returns to its natural state between spring 120 and spring 185.
[0085] Although the longitudinal axis Lc of the cylinder 103 is
shown as being substantially normal to the longitudinal axis Lp of
the valve pocket 138 and the longitudinal axis Lv of the valve
member 160, in some embodiments, the longitudinal axis of the
cylinder can be offset from the longitudinal axis of the valve
pocket and/or the longitudinal axis of the valve member by an angle
other than 90 degrees.
[0086] Although the flow passages 168 and the cylinder flow
passages 148 are shown as having particular shapes in FIG. 1, the
flow passages 168 and the cylinder flow passages 148 can have any
suitable shape. FIG. 1 shows the flow passages 168 having rounded
tops. When aligned as in FIG. 1, the flow passages 168 and the
cylinder flow passages 148 can have a combined converging/diverging
shape. In some embodiments, when the valve member 160 is in the
open configuration, at least one of the valve flow passages 168 can
converge toward a corresponding cylinder flow passage 148, and the
corresponding cylinder flow passage 148 can converge toward at
least one of the valve flow passages 168. In some embodiments, at
least one of the valve flow passages 168 and the cylinder flow
passages have a central axis angled at a non-zero angle relative to
the central axis Lc of the cylinder head 132. In some embodiments,
the flow passages 168 and/or the cylinder flow passages 148 can be
angled, for example, 5, 10, or 20 degrees relative to vertical to
control the fluid motion inside the cylinder 103 when the piston
inside the cylinder 103 is drawing down. In some embodiments, the
flow passages 168 and/or the cylinder flow passages 148 can be
angled between, for example, about 20 degrees and about 40 degrees
relative to vertical. In some embodiments, the flow passages 168
and/or the cylinder flow passages 148 can be angled, for example,
between about 5 degrees and about 20 degrees relative to vertical.
The flow passages 168 and/or the cylinder flow passages 148 can
have optimized shapes and sizes such that the fluid flow can be
controlled to achieve a particular result. For example, tumble can
occur such that air flows down one side of the cylinder 103, starts
to rotate near the piston at the bottom of the cylinder, and then
is collapsed and converted into turbulence such that fuel
efficiency is improved.
[0087] The spring 122 and the spring 185 can be constructed from
any suitable material, such as, for example, a stainless steel
spring wire, and can be fabricated to produce a suitable biasing
force. In some embodiments, however, a cylinder head assembly can
include any suitable biasing member to ensure that that the valve
member 160 can be moved among a center-biased equilibrium
configuration, an opened configuration, and a closed configuration.
For example, in some embodiments, a cylinder head assembly can
include a cantilever spring, a Belleville spring, a leaf spring and
the like.
[0088] Although the cylinder head 132 is shown and described as
being a separate component coupled to the engine block 102, in some
embodiments, the cylinder head 132 and the engine block 102 can be
monolithically fabricated, thereby eliminating the need for a
cylinder head gasket and cylinder head mounting bolts. In some
embodiments, for example, the engine block and the cylinder head
can be cast using a single mold and subsequently machined to
include the cylinders, valve pockets and the like.
[0089] Although the engine 100 is shown and described as including
a single cylinder, in some embodiments, an engine can include any
number of cylinders in any arrangement. For example, in some
embodiments, an engine can include any number of cylinders in an
in-line arrangement. In other embodiments, any number of cylinders
can be arranged in a vee configuration, an opposed configuration or
a radial configuration.
[0090] Similarly, the engine 100 can employ any suitable
thermodynamic cycle. Such engine types can include, for example,
Diesel engines, spark ignition engines, homogeneous charge
compression ignition (HCCI) engines, two-stroke engines and/or four
stroke engines. Moreover, the engine 100 can include any suitable
type of fuel injection system, such as, for example, multi-port
fuel injection, direct injection into the cylinder, carburetion,
and the like.
[0091] Although the cylinder head assembly 130 is shown and
described above with reference to a single valve 160 and a single
gas manifold 110, in some embodiments, a cylinder head assembly
includes multiple valves and gas manifolds. For example, FIG. 4
illustrates a perspective view of a cylinder head assembly 230. As
illustrated, the cylinder head assembly 230 includes four cylinder
heads 232. Each cylinder head 232 includes an intake valve member
260I and an exhaust valve member 260E (shown in perspective view in
FIGS. 5 and 6, respectively). Each of the cylinder heads 232 can be
the same or similar in structure and/or function to the cylinder
head 132 described above with reference to FIG. 1. For example,
each of the cylinder heads 232 is associated with two solenoid
assemblies 280 and two spring assemblies 220 (one of each for both
the intake valve member 260I and the exhaust valve member 260E).
Each solenoid assembly 280 and spring assembly 220 can be the same
or similar in structure and/or function to the solenoid assembly
180 and spring assembly 120, respectively.
[0092] Each cylinder head 232 can include an intake valve pocket
(not shown), within which the intake valve member 260I can be
disposed, and an exhaust valve pocket (not shown), within which the
exhaust valve member 260E can be disposed. Each cylinder head 232
can define an intake port 237 and an exhaust port 239. The
positioning of the intake valve member 260I and the exhaust valve
member 260E relative to cylinder flow passages defined by each
cylinder head 232 can be controlled by the solenoid assembly 280
and the spring assembly 220 as described above with respect to the
solenoid assembly 180 and the spring assembly 120. For example, the
operation of each intake valve member 260I and each exhaust valve
member 260E can be similar to that of the valve member 160
described above in that each has an equilibrium position, an opened
position, and a closed position. When the intake valve member 260I
is in the opened position, in which each flow passage 268I defined
by the intake valve member 260I is aligned with a corresponding
cylinder flow passage (not shown), an intake manifold (not shown)
coupled to the cylinder head can be in fluid communication with a
cylinder (not shown) coupled to the cylinder head, thereby allowing
a charge of air to be conveyed from the intake manifold into the
cylinder. When the exhaust valve member 260E is in the closed
position in which each flow passage 268E of the exhaust valve
member 260E is fully offset and/or sealed from its corresponding
cylinder flow passage (not shown), each flow passage 268E can be
fluidically isolated from the cylinder flow passages (not shown).
In this manner, the cylinder can be fluidically isolated from the
exhaust manifold (not shown).
[0093] The cylinder head assembly 230 can have many different
configurations corresponding to the various combinations of the
positions of the valve members 260I, 260E within each cylinder head
232 as the valve members 260I, 260E move between their respective
equilibrium, opened and closed positions. One possible
configuration of a cylinder head 232 includes an intake
configuration in which the intake valve member 260I is in the
opened position and the exhaust valve member 260E is in the closed
position. Another possible configuration includes a combustion
configuration in which both valves are in their closed positions.
Yet another possible configuration includes an exhaust
configuration in which the intake valve member 260I is in the
closed position and the exhaust valve member 260E is in the opened
position. Yet another possible configuration is an overlap
configuration in which both valves are in their opened
positions.
[0094] Although the intake valve member 260I and the exhaust valve
member 260E are shown in FIGS. 5 and 6 as defining eight flow
passages each having a long, narrow shape, in some embodiments a
valve member can define any number of flow passages having any
suitable shape and size. Each flow passage 268I and 268E need not
have the same shape and/or size as the other flow passages 268I and
268E. Rather, in some embodiments, the size of the flow passages
can decrease with a taper of the valve member 260I and/or 260E. In
this manner, the valve member 260 can be configured to maximize the
cumulative flow area, thereby resulting in more efficient engine
operation. Moreover, in some embodiments, the shape and/or size of
the flow passages 268 can vary along a longitudinal axis of the
flow passages 268I and 268E. For example, in some embodiments, the
flow passages can have a lead-in chamfer or taper along the
longitudinal axis of the flow passages 268I and 268E. In some
embodiments, the flow passages 268I and/or 268E near the ends of
the intake valve member 260I or the exhaust valve member 260E can
have shorter lengths than the flow passages 268I and/or 268E in the
center of the intake valve member 260I or the exhaust valve member
260E.
[0095] Similarly, each of the cylinder flow passages (such as
cylinder flow passages 148 in FIG. 1) need not have the same shape
and/or size as the other cylinder flow passages, respectively.
Moreover, in some embodiments, the shape and/or size of the
cylinder flow passages (e.g., 148) can vary along their respective
longitudinal axes. For example, in some embodiments, the cylinder
flow passages can have a lead-in chamfer or taper along their
longitudinal axes. In some embodiments, the cylinder flow passages
(e.g., 148) corresponding to the valve flow passages 268I or 268E
near the ends of the intake valve member 260I or the exhaust valve
member 260E, respectively, can have shorter lengths than the
cylinder flow passages in the center of the cylinder flow passage
arrangement (e.g., near the center of the bridge portion).
[0096] In some embodiments, the longitudinal axis and/or the
centerline of one flow passage (e.g., the cylinder flow passages
148 and/or the valve flow passages 168) need not be parallel to the
longitudinal axis of another flow passage, as shown in FIG. 1.
Additionally, as shown in FIG. 1, in some embodiments the
longitudinal axis Lf of one or more of the flow passages 168 can be
substantially normal to the longitudinal axis Lv of the valve
member 160, while the longitudinal axis Lf of other of the flow
passages 168 can be angularly offset from the longitudinal axis Lv
of the valve member 160 by an angle other than 90 degrees.
[0097] The valve members 260I and 260E can be fabricated from any
suitable material or combination of materials. For example, in some
embodiments, the tapered portion can be fabricated from a first
material, the stem portions can be fabricated from a second
material different from the first material and the sealing
portions, to the extent that they are separately formed, can be
fabricated from a third material different from the first two
materials. In this manner, each portion of the valve member can be
constructed from a material that is best suited for its intended
function. For example, in some embodiments, the sealing portions
can be fabricated from a relatively soft stainless steel, such as
for example, unhardened 430FR stainless steel, so that the sealing
portions will readily wear when contacting the interior surface of
the cylinder head. In this manner, the valve member can be
continuously lapped during use, thereby ensuring a fluid-tight
seal. In some embodiments, for example, the tapered portion can be
fabricated from a relatively hard material having high strength,
such as for example, hardened 440 stainless steel. Such a material
can provide the necessary strength and/or hardness to resist
failure that may result from repeated exposure to high temperature
exhaust gas. In some embodiments, for example, one or both stem
portions can be fabricated from a ceramic material configured to
have high compressive strength.
[0098] In some embodiments, each of the cylinder heads 232,
including the interior surface (not shown) that defines the valve
pocket, is monolithically constructed from a single material, such
as, for example, cast iron. In some monolithic embodiments, for
example, the interior surface defining the valve pocket can be
machined to provide a suitable surface for engaging the sealing
portions (not shown) of the valve member such that a fluid-tight
seal can be formed. In other embodiments, however, the cylinder
head can be fabricated from any suitable combination of materials.
As discussed in more detail herein, in some embodiments, a cylinder
head can include one or more valve inserts disposed within the
valve pocket. In this manner, the portion of the interior surface
configured to contact the sealing portions of the valve member can
be constructed from a material and/or in a manner conducive to
providing a fluid-tight seal.
[0099] FIGS. 7 and 8 are each a perspective view of the assembly of
FIG. 4 in a first exploded configuration and a second exploded
configuration, respectively. As shown in FIGS. 7 and 8, the spring
or return assemblies 220 can include a housing 223. As demonstrated
by FIG. 7, in some embodiments, each of the cylinder heads 232 can
first be assembled such that the cylinder head 232 defines an
intake valve pocket and an exhaust valve pocket (not shown). The
cylinder head 232 can be formed such that, in the assembled
configuration, the cylinder head 232 defines an intake actuator
assembly port 292I and an exhaust actuator assembly port 292E on a
first side of the cylinder head 232, and an intake return assembly
port 293I and an exhaust return assembly port 293E (not shown) on a
second side of the cylinder head 232. Each of the actuator
assemblies 280 can be inserted into one of the intake actuator
assembly port 292I and the exhaust actuator assembly port 292E. The
intake valve member 260I can be inserted through the intake return
assembly port 293I and into the intake valve pocket. The exhaust
valve member 260E can be inserted through the exhaust return
assembly port 293E and into the exhaust valve pocket. Each of the
return assemblies 220 can then be inserted into one of the intake
return assembly port 293I and the exhaust return assembly port
293E.
[0100] FIG. 48 is a cross-sectional illustration of a cylinder head
3430 and a valve member 3460. The cylinder head 3430 and the valve
member 3460 can be the same or similar in structure and/or function
to any of the cylinder heads or valve members, respectively,
described herein. For example, the cylinder head 3430 includes a
cylinder bridge 3494. The cylinder bridge 3494 includes a number of
sealing portions 3455 that define a number of flow passages 3448.
The valve member 3460 includes a valve bridge 3462. The valve
bridge 3462 includes a number of sealing portions 3472 that define
a number of flow passages 3468.
[0101] The valve member 3460 is shown in FIG. 48 in a neutral,
center-biased mid-position within the cylinder head 3430. Said
another way, the valve member 3460 is shown in a position that is
located partially between the fully closed and fully open position.
The valve member 3460 can be biased toward the shown center-biased
configuration when an actuator assembly (not shown) on a first side
of the valve member 3460 is not applying force via a solenoid
assembly, but is providing force to a first side of the valve
member 3460 via a spring and a return assembly (not shown) is
applying a force via a spring to a second side of the valve member
3460. In some embodiments, the exhaust port 3439 and the combustion
chamber 3409 can be in fluid communication when the valve member
3460 is in the neutral, center-biased position. In some
embodiments, the valve member 3460 can partially or fully seal the
exhaust port 3439 from the combustion chamber 3409 in the
center-biased position, although the valve member 3460 is in a
longitudinally translated position relative to the fully closed
position of the valve member 3460 (e.g., the seal may be less
strong in the center-biased position). In some embodiments, an edge
of a sealing member 3472 can align with an edge of a sealing member
3455 in the center-biased position of the valve member 3460. In
some embodiments, an edge of a sealing member 3472 can be offset
from an edge of a sealing member 3455 when the valve member 3460 is
in the center-biased position.
[0102] As shown in FIG. 48, in some embodiments the cylinder head
can include a number of cooling passages 345I. The cooling passages
345I can extend through, for example, the sealing members 3455. The
cooling passages 345I can be in fluidic communication with a source
of coolant such that the coolant can flow through the sealing
members 3455 of the valve member 3460 and cool the valve member
3460. Although FIG. 48 shows the cooling passages 345I extending
through two of the sealing member 3455, in some embodiments the
cooling passages 345I can be defined through any portion of the
valve member 3460 and any number of sealing members 3455, such as,
for example, one or all of the sealing member 3455.
[0103] FIG. 9 is a perspective view of a portion of an engine 300
including a cylinder head assembly 330, according to an embodiment.
The cylinder head assembly 330 can be the same or similar in
structure and/or function to any of the cylinder head assemblies
described herein. For example, the cylinder head assembly 330
includes a cylinder head 332, which can be the same or similar in
structure and/or function to any of the cylinder heads described
herein. Additionally, actuation assemblies 380I and 380E (e.g.,
solenoid assemblies) can be coupled to the cylinder head 332 such
that the actuation assemblies 380I and 380E can be operationally
coupled to an intake valve member (not shown) and an exhaust valve
member (not shown) disposed within an intake valve member pocket
(not shown) and an exhaust valve member pocket (not shown),
respectively. The actuation assemblies 380I and 380E can be the
same or similar in structure and/or function to any actuation
assemblies or solenoid assemblies described herein. Additionally,
return assemblies 320 (e.g., spring assemblies) can be coupled to
the cylinder head 332 such that the return assemblies 320 are
operationally coupled to the intake valve member and the exhaust
valve member. The return assemblies 320 can be the same or similar
in structure and/or function to any of the return assemblies or
spring assemblies described herein. Additionally, an intake duct
310I and an exhaust duct 310E are coupled to the cylinder head 332
such that the intake duct 310I is in fluid communication with an
intake port (not shown) and, thus, the flow passages of the intake
valve member and such that the exhaust duct 310E is in fluid
communication with an exhaust port (not shown) and, thus, the flow
passages of the exhaust valve member.
[0104] FIG. 10 is a perspective view of a cylinder head assembly
430, according to an embodiment. The cylinder head assembly 430 can
be the same and/or similar in structure and function to the
cylinder head assembly 230 described above with respect to FIGS.
4-8. For example, the cylinder head assembly 430 includes four
cylinder heads 432. An outer wall of each cylinder head 432 of the
cylinder head assembly 430 is shown in transparent in FIG. 10 such
that the inner components of each cylinder head 432 can be viewed.
As shown in FIG. 10, an fluid injector and/or spark plug can be
positioned through the center of each cylinder head 432 such that
the fluid injector and/or spark plug are able to access a
combustion chamber below the cylinder head 432.
[0105] FIG. 11 is a perspective view of a cylinder head assembly
530, according to an embodiment. The cylinder head assembly 530
includes a cylinder head 532, which can be the same or similar in
structure and/or function to any of the cylinder heads described
herein. Additionally, actuation assemblies 580I and 580E (e.g.,
solenoid assemblies) are coupled to the cylinder head 532 such that
the actuation assemblies 580I and 580E can be operationally coupled
to an intake valve member 560I and an exhaust valve member (not
shown) disposed within an intake valve member pocket (shown via
cutaway of a portion of the cylinder head 532) and an exhaust valve
member pocket (not shown), respectively. The actuation assemblies
580I and 580E can be the same or similar in structure and/or
function to any actuation assemblies or solenoid assemblies
described herein. Additionally, return assemblies 520 (e.g., spring
assemblies) are coupled to the cylinder head 532 such that the
return assemblies 520 are operationally coupled to the intake valve
member and the exhaust valve member. The return assemblies 520 can
be the same or similar in structure and/or function to any of the
return assemblies or spring assemblies described herein.
[0106] FIG. 12 is a perspective view of a cylinder head assembly
630, according to an embodiment. The cylinder head assembly 630
includes a cylinder head 632, which can be the same or similar in
structure and/or function to any of the cylinder heads described
herein. Additionally, actuation assemblies 680I and 680E (e.g.,
solenoid assemblies) are coupled to the cylinder head 632 such that
the actuation assemblies 680I and 680E can be operationally coupled
to an intake valve member 660I and an exhaust valve member (not
shown) disposed within an intake valve member pocket (shown via
cutaway of a portion of the cylinder head 632) and an exhaust valve
member pocket (not shown), respectively. The actuation assemblies
680I and 680E can be the same or similar in structure and/or
function to any actuation assemblies or solenoid assemblies
described herein. Additionally, return assemblies 620 (e.g., spring
assemblies) are coupled to the cylinder head 632 such that the
return assemblies 620 are operationally coupled to the intake valve
member and the exhaust valve member. The return assemblies 620 can
be the same or similar in structure and/or function to any of the
return assemblies or spring assemblies described herein. The
cylinder head 632 also defines an intake port 637 and an exhaust
port 639, such that, when an intake manifold is fluidically coupled
to the intake port 637 and an exhaust manifold is fluidically
coupled to the exhaust port 639, the intake manifold is in fluidic
communication with the flow passages of the intake valve member
660I and the exhaust manifold is in fluid communication with the
flow passages of the exhaust valve member.
[0107] In some embodiments, the flow passage portion of a valve
member, such as any of the valve members described herein, defining
the flow passages of the valve member (i.e., the valve bridge) and
the portion of a cylinder head, such as any of the cylinder heads
described herein, defining the cylinder flow passages (i.e., the
cylinder bridge) can be designed, shaped, and formed such that
distortion and stress over operating temperature and pressure
ranges is reduced. For example, the valve bridge and the cylinder
bridge can be shaped and formed such that the distortion and stress
is reduced when used in a modern combustion engine.
[0108] In some embodiments, the bridges can be S-shaped and/or
Z-shaped such that stresses are allowed to deform the bridge in a
controlled and desired manner. For example, the flow passages
through the cylinder bridge and/or the valve bridge can be arranged
and sized such that the sealing portions of the cylinder bridge or
valve bridge, respectively, have an S or Z shape. In some
embodiments, the outer shape or periphery of the valve bridge can
have an S or Z shape. In some embodiments, the ratio of height to
width of the valve bridge and/or the cylinder bridge can be greater
than 1. In some embodiments, the stiffness of the cylinder head can
be reduced to allow for the expansion and deformation of the
bridges without inducing high stresses. In some embodiments, a
freely expanding combustion ring or insert can be included. The
freely expanding combustion ring or insert can be configured to not
transfer load into the main cylinder head and can enable controlled
deformation resulting from thermal and mechanical loads. In some
embodiments, the valve bridge and/or the cylinder bridge can be
structured to handle peak cylinder pressures. For example, the
valve bridge and/or the cylinder bridge can include stress
optimization through the bridge contour such that the valve bridge
and/or the cylinder bridge can have a thick center and thinner
ends.
[0109] In some embodiments, a cylinder head, such as any of the
cylinder heads described herein, can be manufactured from one
material. In some embodiments, a cylinder head, such as any of the
cylinder heads described herein, can be manufactured from two or
more materials. For example, one of the materials can be a
high-strength material such that the high-strength material
provides an internal (e.g., skeletal) or an external (e.g.,
exoskeletal) framework and/or is able to accommodate thermal and
mechanical loads.
[0110] In some embodiments, the valve can be manufactured as a
compacted graphite iron (CGI) casting. In some embodiments, the
cooling of the casting during manufacturing can be controlled to
improve strength in high-stress areas. The rate of cooling can
affect the microstructure of the casting, and, in turn, physical
properties like conductivity, strength, and other properties.
[0111] In some embodiments, the valve member and cylinder head can
be formed from materials selected to achieve desired physical
characteristics to enable proper operation over the operating
temperature and pressure ranges. Additionally, the valve member and
cylinder head can be formed from a material that achieves desired
performance characteristics at a low cost. For example, the valve
member and cylinder head can be formed from compacted graphite
iron. In some embodiments, the valve member and cylinder head can
be formed from, for example, ceramic materials and/or 3D printed
materials. In some embodiments, the valve member and cylinder can
be formed from any material capable of maintaining stable
mechanical properties up to temperatures exceeding 450 C and having
a high thermal conductivity such that the operational temperature
of the components can be maintained.
[0112] In some embodiments, methods can be used to cool the valve
member and the cylinder head to proper operation temperatures of
the valve member and the cylinder head over the operating range of
the engine. In some embodiments, the valve member can have
increased surface area on the top side of the valve member to
transfer heat to the cool portion of the cylinder head away from
the combustion heat loads. For example, the top surface, including
the top sides of the sealing portions, can have a concave shape
such that the top surface has more surface area for heat transfer.
An example of this can be seen in FIG. 47, which is a perspective
view of a valve member 3360. The valve member 3360 can be the same
or similar in structure and/or function to any of the valve members
described herein. The valve member 3360 includes a flow passage
portion 3362. As shown, the flow passage portion 3362 is surrounded
by a first upper wall 3398 and a second tapered upper wall 3397.
The flow passage portion 3362 includes a number of sealing portions
3372 and defines a number of flow passages 3368. The top surface of
the flow passage portion 3362 is concave such that the edges of the
flow passage portion 3362 including the end portions of the sealing
portions 3372 curve upward toward the edge of the first upper wall
3398 and/or the second tapered upper wall 3397. Thus, the valve
member 3360 can have an increased upper surface area for heat
transfer.
[0113] In some embodiments, the valve bridge and/or the cylinder
bridge can define cooling passages through the valve bridge and/or
the cylinder bridge. For example, the cooling passages can be
defined during a 3D printing process of the valve bridge and/or the
cylinder bridge. In some embodiments, the valve member, the valve
bridge, and/or the cylinder bridge can include (e.g., be filled
with) sodium. In some embodiments, the valve member, the valve
bridge, and/or the cylinder bridge can define cooling channels that
are shaped to guide heat away from the valve member, the valve
bridge, and/or the cylinder bridge. In some embodiments, the head
can be cooled independently from the cylinder block such that
cooler temperatures are allowed from the coolant while normal
operating temperatures are still allowed in the cylinder block. For
example, coolant lines can be run directly from a coolant pump to
the cylinder head. In some embodiments, a dedicated cooling circuit
can be coupled to the cylinder head. In some embodiments, thermal
barrier coatings can be used to restrict the conduction of heat
from the gas to the valve and cylinder head. In some embodiments, a
water-cooled exhaust manifold can be included. For example, the
water-cooled exhaust manifold can be 3D printed.
[0114] In some embodiments, copper heat conduits can be imbedded in
the valve member and/or the cylinder bridge. In some embodiments,
the copper heat conduits can be formed (e.g., printed) with
integrated porous wicking features. In some embodiments, during
manufacture of a CGI casting of the valve and/or the head, the
cooling of the casting can be controlled to improve conductivity
along critical heat transfer paths. In some embodiments, 3D printed
structures can be incorporated into cooling channels defined in the
valve member, the valve bridge, and/or the cylinder bridge to
improve heat transfer compared to conventional cooling channels.
The 3D printed structures can cause the cooling channels to have
increased surface area. In some embodiments, the 3D printed
structures can be formed as webs, matrices, honey combs,
micro-fins, scaffolding, and/or micro-channels. In some
embodiments, the cooling channels can be optimized for maximum heat
transfer coefficient using 3D printing. For example, the surface
roughness can be optimized to increase flow for a given pump
pressure. In other embodiments, turbulence can be strategically
introduced in flow passages that may otherwise tend to be laminar
via structures coupled (e.g., via 3D printing or molding) to the
interior walls of the flow passages.
[0115] In some embodiments, the cylinder head assembly can be
designed to reduce and stabilize the friction of the moving
components in the cylinder head over the operating range and life
of the engine. For example, the cylinder head assembly can include
features to reduce friction of the moving components in the system
while still allowing for a non-lubricated system capable of
operating at elevated temperatures. In some embodiments, the
contact area for friction, and resultant heat transfer, can be
reduced. In some embodiments, coatings can be applied to the moving
components to allow composite bearing materials to achieve the
targeted operating life goals. In some embodiments, the valve
members can be shaped and sized relative to their corresponding
valve pockets such that sufficient tolerance between the valve
members and their corresponding valve pockets exists such that the
sides of the valve members are not in contact the cylinder head,
which would induce uncontrolled frictional loading. In some
embodiments, self-aligning guides can be included to reduce force
from binding or misalignment. In some embodiments, the angle of
operation (i.e., the line of action) can be adjusted such that the
valve member is raised and the majority of the contact area is
eliminated.
[0116] Due to the wedging force needed to hold the valve member in
position relative to the cylinder head (e.g., in a closed
configuration), the valve member can require a significant force to
initiate movement out of wedged engagement with the cylinder head.
In some embodiments, a slide hammer can be used to initiate this
movement. In some embodiments, the stress caused by the slide
hammer impact forces can be reduced over the operating range and
life of the engine. For example, in some embodiments, a contact
button can be included to survive the high impact load and
distribute the force to a larger area on the valve to reduce
stress. A contact button can be disposed on and/or within each
valve stem of a valve member. In some embodiments, the contact
button can be the same as a plug (e.g., first plug 178). In some
embodiments, the contact button can be in addition to a plug. In
some embodiments, a stiffener can be included in the center of the
valve member to distribute the loads within the valve member. In
some embodiments, fingers or a rib can be included (e.g., during
casting of the valve) running down the sides of the valve member to
direct the loads into the stronger sides of the valve member and
away from the bridges.
[0117] In some embodiments, a valve member, such as any of the
valve members described herein, can be manufactured with multiple
materials. For example, a high-strength material can be used to
provide an internal (e.g., skeletal) or external (e.g.,
exoskeletal) framework to accommodate slide hammer loads without
affecting the form or function of the valve member. In some
embodiments, an adjustable spring can be included in the contact
button such that the slide hammer loads can break the valve member
free while not introducing excessive impact force on the valve
member.
[0118] In some embodiments, the volumetric efficiency can be
improved by controlling the air motion in the cylinder for
combustion purposes over the operating range and life of the
engine. In some embodiments, the angle of the intake valve slots
(e.g., the flow passages 168 of valve member 160 of FIG. 1) can
align with the bore of the cylinder to create high tumble
scenarios. In some embodiments, the intake valve slots can be
angled away from parallel to create a desired combination of swirl
and tumble. FIGS. 13A and 13B illustrate an intake valve member
760I and an exhaust valve member 760E. The intake valve member 760I
defines intake valve passages 768I (also referred to as intake
valve slots) defined at a 20-degree angle. When simulated in
computational fluid dynamics (CFD) software, the 20-degree angle
resulted in only a slight reduction in volumetric efficiency and
still maintained a volumetric efficiency of greater than 100%. The
angle of the intake valve slots can be designed to take advantage
of the varying air velocities to over the operating conditions of
the engine to create different air motion characteristics within
the cylinder. Additionally, the valve bridge and/or the cylinder
bridge can be structured (e.g., via angling of the intake valve
passages ad/or the valve passages in the cylinder bridge) to manage
conversion of swirl and tumble conversion into kinetic energy
without dissipating the energy in the slot volumes. In some
embodiments, the intake valve slots or flow passages can have any
suitable shape or size. For example, FIGS. 44A and 44B illustrate
two possible flow passage cross-section shapes.
[0119] In some embodiments, a valve member, such as any of the
valve members described herein, can be structured to improve the
flow of air into and out of the cylinder over the operating range
and life of the engine. In some embodiment, the valve member
structure results in a reduced flow area compared to conventional
poppet valves and enables the incorporation of several design
features which result in very high discharge coefficients. The
resultant effective flow into the cylinder is very similar. In some
embodiments, a converging or diverging geometry can be defined in
the flow passages or slots (e.g., see FIG. 35B). In some
embodiments, a tripping feature or lip can be added to create
turbulence and maintain contact of the flow with the wall. In some
embodiments, flow areas can be reduced in the inlet and exhaust
manifolds to improve packaging and allow for the ability to keep
flow attached.
[0120] In some embodiments, the architectural geometry of the valve
members and the cylinder head can be configured to optimize
performance and packaging over the operating range and life of the
engine. The valve members, such as any of the valve members
described herein, can be packaged in many different configurations
depending on the primary need of the intended design. This
flexibility allows for very accommodating and unique capabilities
to meet customer performance and packaging requirements. For
example, the valve members can include a cross flow design, a
non-cross flow design, longitudinal flow, log manifold, boot-heel
valve packaging, various valve seat angles (wedge angles),
removable valve seats, head resurfacing for re-work, packaging
considerations for a GDI injector next to an exhaust header, and/or
spray angles and spark plug interactions for GDI.
[0121] In some embodiments, a system includes a
centrally-biased-spring-return actuator controlled engine valve
system. The system minimizes packaging, friction, alignment issues
and cost. FIG. 14 illustrates a system including a cylinder head
assembly 1730 where the design locates two actuators (e.g., both an
open and a close holding solenoid, 1782 and 1786, respectively) and
a return spring 1759 on the nose-end side of the valve member 1760
while retaining a lash feature. The combined actuator includes one
armature 1787 rather than separate actuators. A second spring 1722
is located on the opposite side of the valve member 1760, as shown
in FIG. 14. The lash area 1764 combines an optional lash zone and
guidance separation location. The actuator's armature 1787 is
mechanically guided separately from the valve's guidance. The
spring locations keep the armature 1787 and the valve member 1760
together throughout the opening and closing cycle. Said another
way, the springs 1759 and 1722 are center-biased, keeping the two
bodies (i.e., the valve member 1760 and the force application
member 1784) in contact, except on the seat, as shown in FIG. 14.
The configuration's opening spring contributes to high velocities
prior to lash gap takeup, leading to lower required gaps. The
design also contributes to easier actuation access sealing. The
springs 1759 and 1722 can be sized to have appropriate forces at
end-of-travel, controlling typical valve bounce. With respect to
alignment, the system has clean divorce of actuator and valve
movement centerlines and guidance. Including only one armature 1787
reduces the mass of the system and the number of connections. When
the lash 1764 is adjusted to zero, the system is center-biased and
there is low friction connection. The system includes easy valve
seal on the armature. The slidehammer can be easily adjusted.
Additionally, the slidehammer can directly act on the valve member.
Impulse can be directed through the valve's center-of-gravity.
[0122] In some embodiments, compression pulses can be reduced or
eliminated during engine starting or stopping transients for the
purpose of improved noise, vibration, and harshness (NVH) through
the use of specific intake and/or exhaust valve timing. This is a
common disturbance for automotive hybrid powertrains, including
simple start/stop systems used for improved fuel economy. The
systems described herein allow completely decoupled valve events
relative to piston/crankshaft position, from both dynamic timing
and valve-to-piston clearance perspectives, and can change function
strategy cycle-by-cycle and cylinder-by-cylinder. As such,
either/both intake and exhaust valve timing can be adjusted in
various strategies to negate cylinder compression and its attendant
engine dynamic motion. One strategy embodiment would allow the
intake air charge normally drawn into the cylinder to return to the
intake manifold during the compression stroke, while then opening
the exhaust valve during the "power` stroke to similarly
recirculate exhaust gas. Variations and permutations of this
strategy are numerous, depending upon emission, engine
configuration, noise, and other factors. Typical engine starts in
dynamic hybrid or start/stop driving operation can be either
urgently fast or transparently subdued. The systems described
herein facilitate either type of start by allowing a range in the
number of engine compression events to be suppressed while the
engine reaches an optimal target speed before normal valve timing
is returned and combustion resumes. Engine shut-off can be a
combination of normal compression or compression release free spin
down.
[0123] In some embodiments, transient combustion power generation
can be managed during gasoline engine starts using throttle-less
fully-flexible intake valve control. This is a common disturbance
for automotive hybrid powertrains, including simple start/stop
systems used for improved fuel economy. Conventionally throttled
gasoline hybrid and start/stop automotive powertrains often restart
the engine with crankshaft motion of less than one revolution. The
initial firing cylinder charge may be at nearly atmospheric
pressure, resulting in a large combustion power pulse. This is due
to intake manifold volume, below the throttle, shared by all
cylinders. Subsequent firing cylinders have incrementally reduced
power pulses as the intake manifold is evacuated. The system
described herein allows fully flexible intake and exhaust valve
timing/flow, and can change function strategy cycle-by-cycle and
cylinder-by-cylinder. This control method commands the first viable
combustion cylinder, and subsequent cylinders, to have reduced
power via the cylinder-mounted valve member. Numerous throttle-less
control strategies using valve timing can be executed to deliver
the requested power levels. The return to normal engine power can
be a pre-defined transition profile, depending upon driver and
overall vehicle desired response characteristic. Thus, the systems
described herein can provide a smooth, repeatable engine start for
vehicle drivability improvement.
[0124] In some embodiments, open loop control of a solenoid
actuated air valve (such as any of the valve members described
herein) can be used to achieve desired valve motion, timing,
velocity and engine performance. The open loop control of a
solenoid(s) actuated air valve to achieve desired valve timing,
valve motion, velocity, electrical power consumption, and/or
specific engine performance by controlling the timing and shape of
solenoid current waveforms referred to here as kicker and catcher
pulses. These open loop algorithms may consist of such features as
fixed pre-calibrated maps for determining kicker and catcher pulse
shape, timing, count, etc. These open loop algorithms may utilize
such engine operating parameters such as speed, temperature, load,
accelerator pedal position, etc. for indexing this pre-calibrated
tables.
[0125] In some embodiments, implementation of kick and catch closed
loop control algorithms for controlling a solenoid actuated air
valve (such as any of the valve members described herein) can be
used to achieve desired valve motion, timing, velocity and engine
performance. Multiple control algorithms can be employed in the
control of a solenoid(s) actuated air valve to achieve desired
valve timing, valve motion, velocity, and/or specific engine
performance by controlling the timing and shape of solenoid current
waveforms referred to here as kicker and catcher pulses. Some of
these control methodologies include: adjusting current on off
timings to achieve desired open and close timings of the valves,
adjusting kicker pulse peak current level and duration as well as
adjusting (e.g., reducing) catcher pulse peak level and duration
reduce in order to reduce electric power consumption, adjusting
kicker and/or catcher to reduce travel time, adjusting catcher
pulse peak level and duration to reduce impact velocity and
ringing/overshoot, controlling kicker pulse characteristics to
achieve desired valve velocity during valve stroke and then
controlling the catcher pulse to set seating velocity, optimizing
algorithms to improve energy consumption, state space or optimal
control to handle inner outer loop inner play, slow and fast loop
rates to reduce multiple control loop interaction, and/or use of
fixed timing points on valve stroke for timing control for example
the point on the valve stroke where the valve starts and stops
breathing.
[0126] In some embodiments, closed loop control of a solenoid
actuated air valve (such as any of the valve members described
herein) can be used to achieve desired valve motion, timing,
velocity, and engine performance. The closed loop control of a
solenoid(s)-actuated air valve to achieve desired valve timing,
valve motion, velocity, and/or specific engine performance can be
achieved by controlling the timing and shape of solenoid current
waveforms referred to here as kicker and catcher pulses. These
control algorithms may utilize standard direct sensing methods such
as analog or limit sensors on valve position or more indirect
sensing methods like cylinder pressure, back EMF, induced currents
in the active and not-active coils, knock sensors, etc. for
feedback purposes. These control algorithms can consist of multiple
control methodologies such as PID, feed forward, dynamic
programming, neural networks, fuzzy logic, adaptive, model
reference adaptive, h-infinity, sliding mode, gain scheduling,
kalman filters, observers, and/or estimators.
[0127] In some embodiments, the sealing surfaces of a cylinder head
flat tapered valve pocket/seat can be defined. This will call out
the surface that is causing the valve to achieve zero clearance at
seal up using a flat taper. In some embodiments, sealing surfaces
can be defined using the chamber bridges as well as the top of the
valve and exit bridges. These also act as cooling contact surfaces
to remove heat from the parts during operation.
[0128] In some embodiments, the cylinder head assemblies described
herein can be testable modules.
[0129] In some embodiments, the cylinder head assemblies described
herein can be oil-less modules. An example cylinder head assembly
1830 in an engine 1800 is illustrated in FIG. 15. As shown in FIG.
15, the design of the valve member 1860, which can be the same or
similar in structure and/or function to any of the valve members
described herein, with the motion perpendicular to the cylinder
bore places the valve guides and actuation device out of the flow
path of the exhaust gas. This enables cooling of the components to
a lower temperature which enables the use of non-lubricated low
friction bushing materials. The linear action method eliminates the
need for rotating components (such as the camshaft) and sliding
wear areas (such as rocker to valve interface) which require
hydrodynamic lubrication and/or oil to reduce friction and wear
between sliding components.
[0130] In some embodiments, the center-biased electromagnetic
actuation of a valve member can reduce power consumption and lower
seating velocities on both the opening and closing of the valve.
The actuator architecture can optionally include a lash distance
between the armature and the valve (i.e., slidehammer gap). In some
embodiments, as shown in an example cylinder head assembly 1930 in
FIG. 16, the actuator architecture can include a push-open, spring
return. In such embodiments, both the opening coil 1982 and the
closing coil 1986 are located on the armature 1987. The opening
spring 1959 is located on the armature, and the closing spring 1922
is located on the opposite side of the valve on the `push-closed
shaft` 1989. Placing both coils on the armature allows for the
implementation of a lash distance 1964, where the armature 1987 is
pulled away from the valve member 1960 when in the closed position,
so that it can provide an impact force to initiate the next valve
opening event. Because the motive forces on the valve are provided
by separate pieces, alignment concerns are mitigated.
[0131] In some embodiments, as shown in the example cylinder
assembly 2030 in FIG. 17, the actuator architecture can include a
push-pull 2065 with integrated slidehammer 2070 such that only an
opening coil 2082 is on the armature 2069. In such embodiments, the
valve member 2060 is centered by opening springs 2059 and closing
springs 2022 acting directly on the valve body 2060. The closing
armature 2087 is also on the valve body. The closing coil 2086 is
on the armature 2087 connected directly to the valve member 2060.
The opening coil 2082 is on the armature 2069, the geometry of
which has a built-in lash to provide the slidehammer effect. The
armature 2069 also has a small biasing spring 2066 to move it to
the correct position between valve events. All the motive forces
(coils and springs) are located on one side of the valve member
2060, which is beneficial from a packaging perspective.
[0132] In some embodiments, as shown in the example cylinder
assembly 2130 in FIG. 18, the actuator architecture can include a
push-pull 2165 with integrated slidehammer 2170, with all
springs/coils on the armature 2169. In such embodiments, the basic
geometry of the assembly 2130 is the same as the assembly 2030 in
FIG. 17, except that all the springs and coils are located on the
armature 2169. That is, the opening and closing coils 2182 and
2186, respectively, as well as the opening and closing springs,
2159 and 2122, respectively, are located on the armature 2169. The
armature 2169 provides all the force to the valve 2160, through the
armature 2187 which is connected directly to the valve member 2160.
The armature 2169 is shaped so that is has a built-in lash as shown
in FIG. 18. Therefore the spring-centering occurs via the armature
2169.
[0133] In some embodiments, as shown in the example cylinder
assembly 2230 in FIG. 19, the actuator architecture can include a
push-pull 2265 with integrated slidehammer 2270, where both the
opening and the closing coils, 2282 and 2286 respectively, are
located on the armature 2269. However, one spring, for example, the
opening spring 2259, is located on the valve member 2260, and one
spring, for example, the closing spring 2222, is located on the
armature 2269. This concept is very similar to that of the
architecture of the cylinder assembly 2130 illustrated in FIG. 18,
except that the opening spring 2259 is located on the valve body
2260 rather than the armature 2269. The spring-centering therefore
is split between the two pieces, the valve 2260 and the armature
2269.
[0134] In some embodiments, as in the example cylinder assembly
2330 shown in FIG. 20, the actuator architecture can include a
push-push 2365, spring-inward, with slidehammer 2370. This concept
uses two armatures 2388 and 2389 on either side of the valve 2360
to push on it. The armature 2389 on the right side has the closing
spring 2322 and the opening coil 2382. The armature on the left
side is split into two pieces 2388A and 2388B. The piece 2388A in
contact with the valve 2360 has the opening spring 2359, the piece
2388B has the closing coil 2386, and a small biasing spring 2366 so
that the valve 2360 resets to the correct position between valve
events. The valve 2360 is therefore centered via the closing
springs and opening springs on the two armatures, which are always
in contact with the valve.
[0135] In some embodiments, as shown in the example assembly 2430
in FIG. 21, the actuator architecture can include a push-pull 2465
without slidehammer. In some embodiments, a lash, or slidehammer
gap, may not be needed. This architecture has a single moving body.
The armature 2487, with both springs, 2422 and 2459, and both
coils, 2482 and 2486, is rigidly fixed to the valve 2460.
[0136] In some embodiments, as shown in the example assembly 2530
in FIG. 22, the actuator architecture can include a push-push 2565
without slidehammer. In some embodiments, a lash, or slidehammer
gap, may not be needed. This architecture utilizes two armatures,
2587 and 2589, one on either side of the valve 2560, each of the
armatures with a coil and spring. For example, the armature 2587
with the closing spring 2522 and the opening coil 2582, and/or the
armature 2587 with the opening spring 2559 and the closing coil
2586. There is no lash between the armatures and valves, so the 3
bodies stay in contact at all times, and thus are centered
together.
[0137] In some embodiments, the geometry of the actuator gap can be
optimized to provide a favorable force output, power consumption,
and controllability of the system. For example, as shown in the
cylinder assembly 2630 in FIG. 23, a single-gap geometry can be
implemented. This actuator geometry utilizes a single
force-creating gap between the armature 2687 and the backiron 2691
for generating electromagnetic force. The primary benefit to this
design is greater force when the gap is larger. FIG. 23 shows an
axi-symmetric cross-section.
[0138] In some embodiments, as shown in FIG. 24, a double-gap
geometry can be implemented. In the example cylinder assembly 2730
in FIG. 24 the actuator geometry utilizes two force-creating gaps
between the armature 2787 and the backiron 2791 for generating
electromagnetic force. The primary benefit to this design is
greater force when the gap is very small. This graphic shows an
axi-symmetric cross-section.
[0139] In some embodiments, a tapered armature can be included, as
shown in the example cylinder assembly 2830 illustrated in FIG. 25.
The moving mass of the system, including the actuator, can be
minimized to achieve fast valve motion with less power consumption.
One way to do this is to use a tapered (i.e., conical-shaped)
armature 2887. The mass of the armature is reduced, with only a
slight angle added to the solid pieces. The change to the
electromagnetic force is negligible compared to the benefit of the
reduced mass. This graphic shows an axi-symmetric
cross-section.
[0140] In some embodiments, the geometry of an electromagnetic
actuator backiron can be optimized to provide a favorable force
output, power consumption, and controllability of the system,
depending on the desired actuator characteristics (e.g., high
force, fast rise time). For example, as shown in FIG. 26, the
backiron 2991 can be non-axisymmetric. The actuator may have a
packaging constraint. For example, the actuator may have a maximum
diameter such that several actuators can be placed side-by-side.
Additional backiron can be added by using a shape that is
rectangular or square, rather than axisymmetric. Additionally, the
armature shape could be made to match the backiron.
[0141] In some embodiments, a flux bender can be included. The area
of the backiron 3091 can be increased, while keeping the armature
the same. The electromagnetic flux is directed from the outside of
the backiron to the smaller dimension armature via an angled piece.
This increases the backiron flux path area, while keeping the pole
area and thus the armature mass the same. An axi-symmetric
cross-section is shown in FIG. 27, with a backiron 3091 and an
armature 3087.
[0142] In some embodiments, the backiron can be formed of a
material chosen to achieve favorable actuator characteristics. For
example, the backiron can be formed from 1006 steel, 1018 steel,
1215 steel, pure iron, and/or 4140 steel.
[0143] In some embodiments, power electronics can be integrated on
a cylinder head. For example, power electronics can be integrated
on any of the cylinder heads described herein. For example,
amplifiers and controls (e.g., all of the amplifiers and controls
necessary for the operation of a cylinder assembly) can be disposed
on a cylinder head of the cylinder assembly to reduce and/or
simplify the wiring harness and connection details. In some
embodiments, the on-head power electronics can result in the
cylinder assembly being a single testable unit. In some
embodiments, all electronics can be oriented on the "cold" intake
side of the cylinder head for protection from the heat. In some
embodiments, the electronics and/or actuators can be cooled by a
cylinder head water jacket. In some embodiments, all of the return
housings and/or springs can be oriented on the "hot" exhaust side
of a cylinder head (such as any of the cylinder heads described
herein) since they are insensitive to the potentially hotter
environment.
[0144] In some embodiments, an actuator assembly, such as any of
the actuator assemblies described herein, can include one or more
valve position sensors.
[0145] In some embodiments, a cylinder head (such as any of the
cylinder heads described herein) can be made of one material. In
some embodiments, the head can be made of two or more materials.
For example, the head can be made of two or more materials such
that the head has reduced weight, only having a heavier material in
particular places or particular areas. For example, a heavier
material can be used in only high wear areas (e.g., CGI valve seats
and an aluminum head).
[0146] In some embodiments, each return housing of a group of
return housings (such as any of the return housings described
herein) can be installed on a cylinder head or combination of
cylinder heads individually. In some embodiments, a number of
return housings can be installed as a group. In some embodiments, a
single snap ring can be used to couple a return housing to a
cylinder head. In some embodiments, a return assembly (such as any
of the return assemblies described herein) can include a return
housing incorporating a seal to keep combustion particles out of
the dead volume.
[0147] In some embodiments, a center bridge can be disposed between
an intake valve pocket and an exhaust valve pocket of a cylinder
head (such as any of the cylinder heads described herein). The
center bridge can be shaped and sized to allow flexibility for
location of a dual spark plug, a pressure transducer, and/or other
components between the intake valve pocket and the exhaust valve
pocket.
[0148] In some embodiments, a total integrated package including a
cylinder head assembly such as any of the cylinder head assemblies
described herein can be about 4 inches lower and about 1 inch
shorter than a conventional OHC cylinder head for in-chassis
packaging benefits.
[0149] In some embodiments, the injector can be positioned in the
section of the cylinder head positioned between the reciprocating
valve members. This placement allows positioning of the injector to
be anywhere ranging from a centered location down to low angle
injection points. The location of the injector can be associated
with the appropriate spark plug location to take advantage of the
fuel/air mixture characteristics to control combustion
characteristic and high heat transfer areas during the combustion
event.
[0150] In some embodiments, a spring or springs associated with an
actuation assembly (such as any of the actuation assemblies
described herein) can be set to locate a valve member (such as any
of the valve members described herein) slightly off center.
Locating the valve member in a neutral position that is slightly
off center can change the velocity profile of the valve member and
the power required to each coil of the actuation assembly to alter
the location or position of the valve member. Thus, the necessary
energy can be reduced for one particular coil (e.g., the open coil
or close coil), the flank velocity can be changed, and varied
seating velocities can be enabled while minimizing total electrical
power to the system.
[0151] In some embodiments, a valve member (such as any of the
valve members described herein) can be oscillated during startup of
an engine and/or a cylinder head assembly to reduce the required
maximum coil force from an actuation assembly. Said another way,
oscillating the valve member one or more oscillations can reduce
the force required from the coil to get the engine valve member
into the desired open and/or closed position for initiating start
of engine operation.
[0152] In some embodiments, one or both coils in an actuation
assembly, such as any of the actuation assemblies described herein,
can be bobbin-less, allowing for more turns in tighter
packaging.
[0153] FIG. 28 shows a cross-sectional front view of a portion of
an engine 800 including a cylinder head assembly capable of
performing fully variable valve actuation, according to an
embodiment. The engine 800 includes an engine block 802 and a
cylinder head assembly 830 coupled to the engine block 802. The
engine block 802 defines or includes a cylinder 803 having a
longitudinal axis Lc. A piston (not shown) can be disposed within
the cylinder 803 such that it can reciprocate along the
longitudinal axis Lc of the cylinder 803. The piston can be coupled
by a connecting rod (not shown) to a crankshaft (not shown) having
an offset throw (not shown) such that as the piston reciprocates
within the cylinder 803, the crankshaft is rotated about its
longitudinal axis (not shown). In this manner, the reciprocating
motion of the piston can be converted into a rotational motion.
[0154] A first surface 835 of the cylinder head assembly 830 can be
coupled to the engine block 802 such that a portion of the first
surface 835 covers the upper portion of the cylinder 803 thereby
forming a combustion chamber 809. Although the portion of the first
surface 835 covering the cylinder 803 is shown as being flat (and,
in some embodiments, lies parallel to the top surface of the piston
within the combustion chamber 109), in some embodiments, because
the cylinder head assembly 830 does not include valves that
protrude into the combustion chamber, the surface of the cylinder
head assembly forming part of the combustion chamber can have any
suitable geometric design. For example, in some embodiments, the
surface of the cylinder head assembly forming part of the
combustion chamber can be curved and angularly offset from the top
surface of the piston. In other embodiments, the surface of the
cylinder head assembly forming part of the combustion chamber can
be curved to form a hemispherical combustion chamber, a pent-roof
combustion chamber or the like.
[0155] An exhaust gas manifold 810E defining an interior area or
port 812 is coupled to a second surface 836 of the cylinder head
assembly 830 such that the interior area 812 of the gas manifold
810 is in fluid communication with a valve pocket 838 (described
below) via an exhaust port 839 in the second surface 836. As
described in detail herein, this arrangement allows a gas, such as,
for example air or combustion by-products, to be transported out of
the cylinder 803 via the cylinder head assembly 830 and the gas
manifold 810. The engine 800 also includes an intake gas manifold
810I coupled to the second surface 836 of the cylinder head 830
such that an interior area (not shown) of the intake gas manifold
810I is in fluid communication with a second valve pocket (not
shown) via an intake port (not shown), and thus the intake gas
manifold 810I can be in fluid communication with the cylinder 803.
Although shown as including two gas manifolds 810E and 810I, in
some embodiments, an engine can include one gas manifold or more
than two gas manifolds.
[0156] Moreover, as shown, in some embodiments the first surface
835 of the cylinder head assembly 830 can be opposite the second
surface 836. In some embodiments, the cylinder head assembly 830 is
arranged such that the flow of gas into and/or out of the cylinder
803 can occur along a substantially straight line. In such an
arrangement, a fuel injector 890 can be disposed in the intake gas
manifold 810I directly above intake cylinder flow passages (such as
cylinder flow passages 148 described above with reference to engine
100). In this manner, the injected fuel can be conveyed into the
cylinder 803 without being subjected to a series of bends.
Eliminating bends along the fuel path can reduce fuel impingement
and/or wall wetting, thereby leading to more efficient engine
performance, such as, for example, improved transient response.
[0157] The cylinder head assembly 830 includes a cylinder head 832
and a valve member 860. The cylinder head 832 has a cylinder bridge
portion 894 (also referred to as a cylinder flow passage portion or
a cylinder bridge). The cylinder bridge 894 of the cylinder head
832 has an interior surface 834 that defines a valve pocket 838
having a longitudinal axis Lp. The cylinder bridge 894 can define
the bottom of the valve pocket 838 and at least a portion of the
top of the combustion chamber 809. The cylinder bridge 894 also
defines nine cylinder flow passages 848. Each of the cylinder flow
passages 848 is adjacent the first surface 835 of the cylinder head
832 and is in fluid communication with the interior of the cylinder
803. Additionally, each of the cylinder flow passages 848 can be in
fluid communication with the valve pocket 838 in a condition where
the cylinder flow passages 848 are not obstructed by the valve
member 860. The cylinder bridge 894 also includes a number of
sealing portions 855 which can define the cylinder flow passages
848.
[0158] The valve member 860 has a flow passage portion 862 (also
referred to herein as a valve bridge or valve bridge portion), a
first stem portion 876, and a second stem portion 877. The valve
member 860 can have an outer wall with a partially tapered shape,
as shown in FIG. 28. The first stem portion 876 is coupled to an
end of the flow passage portion 862 of the valve member 860 and is
configured to engage a first plug 878. The first plug 878 is
configured to engage with an actuator assembly 880 (also referred
to herein as a solenoid assembly). The solenoid assembly 880 can be
the same or similar in structure and/or function as the solenoid
assembly 180 described above with reference to FIGS. 1-3. The
second stem portion 877 is coupled to an end of the flow passage
portion 862 opposite from the first stem portion 876 and is
configured to engage a second plug 879. The second plug 879 is
configured to engage with a spring assembly 820 (also referred to
herein as a return assembly).
[0159] The solenoid assembly 880 includes an armature 881, a
connecting rod 883, a force application member 884, and a spring
885. The solenoid assembly 880 also includes an electromagnetic
open coil 882 and an electromagnetic close coil 886. The force
application member 884 is configured to engage with the first plug
878 such that a force applied to the first plug 878 can cause
movement of the valve member 860. The engagement between the force
application member 884 and the first plug 878 can be abutting
contact. Said another way, the force application member 884 and the
first plug 878 can include no articulated joint or interlocking
features. In other embodiments, the engagement between the force
application member 884 and the first plug 878 and/or the valve
member 860 can include interlocking features.
[0160] The spring assembly 820 includes a spring 822 and a spring
force application member 821. The spring 822 can be configured to
elastically deform and be biased toward an expanded configuration.
The spring force application member 821 can be formed of an
inelastic, stiff material. For example, the spring force
application member 821 can be formed of steel and/or titanium. The
spring force application member 821 is configured to engage with
the second plug 879 such that a force applied to the second plug
879 by the spring assembly 820 (e.g., due to being biased toward an
expanded configuration) can cause movement of the valve member 860.
The engagement between the spring force application member 821 and
the second plug 879 can be abutting contact. Said another way, the
spring force application member 821 and the second plug 879 can
include no articulated joint or interlocking features. In other
embodiments, the engagement between the spring force application
member 821 and the second plug 879 and/or the valve member 860 can
include interlocking features.
[0161] The flow passage portion 862 of the valve member 860 defines
nine flow passages 868 therethrough. The flow passage portion 862
includes a number of sealing portions 872, each of which is
disposed adjacent one of the flow passages 868 and disposed on
and/or includes a bottom surface 863 of the flow passage portion
862. In some embodiments, the sealing portions 872 define the
openings to the flow passages 868 on the bottom surface 863 of the
flow passage portion 862. The valve member 860 is disposed within
the valve pocket 838 such that the flow passage portion 862 of the
valve member 860 can be moved along a longitudinal axis Lv of the
valve member 860 within the valve pocket 838. For example, the
solenoid assembly 880 can be configured to apply a first force to
the first plug 878 such that the valve member 860 shifts in the
direction of arrow D. Similarly, the solenoid assembly 880 can be
configured to apply a second force to the force application member
884 such that the force application member shifts in the direction
of arrow C, causing the valve member 860 to also shift in the
direction of arrow C under the force of the spring assembly 820.
Said another way, the spring assembly 820 can be configured to
apply a force to the second plug 879 such that the valve member 860
shifts in the direction of arrow C.
[0162] The spring 822 and the spring 885 can both be biased toward
the valve member 860 (i.e., the spring 822 and the spring 885 are
both center-biased). Thus, in a configuration in which no current
is applied to the armature 881 of the solenoid assembly 880 (i.e.,
no current is applied to the open coil 882 or the close coil 886),
the spring forces applied to the valve member 860 by the spring 885
and the spring 822 will cause the valve member 860 to be
center-biased in a neutral position such that the valve member 860
is disposed in a centered or substantially centered position
relative to the cylinder head 832 and the valve member 860 is
partially open. In other words, the flow passages 868 can be
partially aligned with the flow passages 848 such that at least a
portion of the cylinder-side opening to each flow passage 868 is in
fluid communication with a flow passage 848 and a portion of the
cylinder-side opening to each flow passage 868 is obstructed,
blocked, or closed by a sealing portion 855. In some embodiments,
the spring 822 and the spring 885 can be biased toward the valve
member 860 such that in the absence of a current applied to the
coils 882, 886 of the solenoid assembly 880, the valve member 860
is disposed halfway between the location of the valve member 860 in
an open position (e.g., the position of the valve member 860 when a
current is applied to the open coil 882) and the location of the
valve member 860 in a closed position (e.g., the position of the
valve member 860 when a current is applied to the close coil
886).
[0163] In some embodiments, the spring 822 and the spring 885 can
be biased toward the valve member 860 such that in the absence of a
current applied to the coils 882, 886 of the solenoid assembly 880,
the valve member 860 is disposed partway along the translation path
between the location of the valve member 860 in an open position
(e.g., the position of the valve member 860 when a current is
applied to the open coil 882) and the location of the valve member
860 in a closed position (e.g., the position of the valve member
860 when a current is applied to the close coil 886). In some
embodiments, the valve member 860 can be positioned closer to the
open position, closer to the closed position, or at the midway
point. In some embodiments, one or more flow passages 868 of the
valve member 860 can be partially obstructed by a sealing portion
872 of the flow passage portion 862. In some embodiments, the
offset in central axes between the flow passages 868 and the
sealing portions 872 when the valve member 860 is in the neutral
position can result in the openings of the flow passages 868 in the
bottom surface 863 of the flow passage portion 862 being about 50%
obstructed, more than 50% obstructed, or less than 50%
obstructed.
[0164] As shown in the configuration of FIG. 28, when the solenoid
assembly 880 is actuated such that current is delivered to the open
coil 882, the armature 881 can be configured to shift toward the
open coil 882, allowing the connecting rod 883 and the force
application member 884 to move into force-applying contact with the
first plug 878 as a result of the force from spring 885. Thus, the
valve member 860 can be pushed by the force application member 884
in the direction of arrow D against the force applied by spring 822
such that the flow passages 868 are in alignment with the flow
passages 848 (as shown by the configuration illustrated in FIG.
28). When the flow passages 868 are in alignment with the flow
passages 848, each of the flow passages 868 can be in fluid
communication with one of the cylinder flow passages 848. In this
manner, the exhaust gas manifold 810E is in fluid communication
with the cylinder 803 via the flow passages 868, 848. When the
current is removed from the open coil 882, a return force applied
by the spring 822 in combination with the spring force application
member 821 can push the valve member 860 in the direction of arrow
C such that the valve member 860 returns to the equilibrium
position.
[0165] When the solenoid assembly 880 is actuated such that current
is delivered to the close coil 886, the armature 881 can be
configured to shift toward the close coil 886, moving the
connecting rod 883 and the force application member 884 in the
direction of arrow C against the force of spring 885 and reducing
the force applied on the first plug 878 by the force application
member 884. Due to the reduced force applied on the first plug 878
by the force application member 884, the valve member 860 can be
pushed by the spring assembly 820 in the direction of arrow C such
that the flow passages 868 are out of alignment with the flow
passages 848. In other words, the valve member 860 can be disposed
such that the flow passages 868 are sealed from the combustion
chamber 109 by the sealing portions 872. Moreover, when each flow
passage 868 is offset from the corresponding cylinder flow passage
848, each flow passage 868 is fluidically isolated from the
cylinder flow passages 848. In this manner, the cylinder 803 is
fluidically isolated from the gas manifold 810. When the current is
removed from the close coil 886, a return force applied by the
spring 885 in combination with the force application member 884 can
push the valve member 860 in the direction of arrow D against the
force of the spring assembly 820 such that the valve member 860
returns to the equilibrium position.
[0166] In some embodiments, the solenoid assembly 880 can be
actuated to apply a "boost pulse" to the valve member 860. For
example, a current can be delivered to one of the open coil 882 or
the close coil 886 to assist movement of the valve (e.g., to
overcome friction forces).
[0167] Although the longitudinal axis Lc of the cylinder 803 is
shown as being substantially normal to the longitudinal axis Lp of
the valve pocket 838 and the longitudinal axis Lv of the valve 860,
in some embodiments, the longitudinal axis of the cylinder can be
offset from the longitudinal axis of the valve pocket and/or the
longitudinal axis of the valve member by an angle other than 90
degrees.
[0168] Although the flow passages 868 and the cylinder flow
passages 848 are shown as having particular shapes in FIG. 28, the
flow passages 868 and the cylinder flow passages 848 can have any
suitable shape. FIG. 28 shows the flow passages 868 having rounded
tops. When aligned as in FIG. 28, the flow passages 868 and the
cylinder flow passages 848 can have a combined converging/diverging
shape. In some embodiments, when the valve member 860 is in the
open configuration, at least one of the valve flow passages 868 can
converge toward a corresponding cylinder flow passage 848, and the
corresponding cylinder flow passage 848 can converge toward at
least one of the valve flow passages 868. In some embodiments, the
flow passages 868 and/or the cylinder flow passages 848 can be
angled, for example, 5, 10, or 20 degrees relative to vertical to
control the fluid motion inside the cylinder 803 when the piston
inside the cylinder 803 is drawing down. In some embodiments, the
flow passages 868 and/or the cylinder flow passages 848 can be
angled between, for example, about 20 degrees and about 40 degrees
relative to vertical. In some embodiments, the flow passages 868
and/or the cylinder flow passages 848 can be angled, for example,
between about 5 degrees and about 20 degrees relative to vertical.
The flow passages 868 and/or the cylinder flow passages 848 can
have optimized shapes and sizes such that the fluid flow can be
controlled to achieve a particular result. For example, tumble can
occur such that air flows down one side of the cylinder 803, starts
to rotate near the piston at the bottom of the cylinder, and then
is collapsed and converted into turbulence such that fuel
efficiency is improved.
[0169] The spring 822 and the spring 885 can be constructed from
any suitable material, such as, for example, a stainless steel
spring wire, and can be fabricated to produce a suitable biasing
force. In some embodiments, however, a cylinder head assembly can
include any suitable biasing member to ensure that that the valve
member 860 can be moved among a center-biased equilibrium
configuration, an opened configuration, and a closed configuration.
For example, in some embodiments, a cylinder head assembly can
include a cantilever spring, a Belleville spring, a leaf spring and
the like.
[0170] Although the cylinder head 832 is shown and described as
being a separate component coupled to the engine block 802, in some
embodiments, the cylinder head 832 and the engine block 802 can be
monolithically fabricated, thereby eliminating the need for a
cylinder head gasket and cylinder head mounting bolts. In some
embodiments, for example, the engine block and the cylinder head
can be cast using a single mold and subsequently machined to
include the cylinders, valve pockets and the like.
[0171] Although the engine 800 is shown and described as including
a single cylinder, in some embodiments, an engine can include any
number of cylinders in any arrangement. For example, in some
embodiments, an engine can include any number of cylinders in an
in-line arrangement. In other embodiments, any number of cylinders
can be arranged in a vee configuration, an opposed configuration or
a radial configuration.
[0172] Similarly, the engine 800 can employ any suitable
thermodynamic cycle. Such engine types can include, for example,
Diesel engines, spark ignition engines, homogeneous charge
compression ignition (HCCI) engines, two-stroke engines and/or four
stroke engines. Moreover, the engine 800 can include any suitable
type of fuel injection system, such as, for example, multi-port
fuel injection, direct injection into the cylinder, carburetion,
and the like.
[0173] FIGS. 29A and 29B show a first perspective view and a second
perspective view of a cylinder head 932, according to an
embodiment. The cylinder head 932 can be the same or similar as any
cylinder head described herein, such as the cylinder head 832 shown
and described above with reference to FIG. 28. The cylinder head
932 includes a top layer 932A, a middle layer 932B, and a bottom
layer 932C. The cylinder head 932 defines an intake port 937 and an
exhaust port 939. The cylinder head 932 is configured to be coupled
to an intake manifold such that the intake manifold is in fluid
communication with the intake port 937 and to an exhaust manifold
such that the exhaust manifold is in fluid communication with the
exhaust port 939. Although the exhaust port 939 is shown as being
narrower than the intake port 937, the exhaust port 939 and the
intake port 937 can have any suitable size and/or shape. The
cylinder head 932, and specifically the top layer 932A, can also
define a spark plug port 927 and a fuel injector port 929 for
engagement with a spark plug (not shown) and a fuel injector (not
shown), respectively. Due to the arrangement of the intake valve
pocket and the exhaust valve pocket within the cylinder head 932, a
spark plug and a fuel injector can be positioned between the intake
valve pocket and the exhaust valve pocket for communication with a
combustion chamber, particular valve pocket, or port associated
with the cylinder head 932.
[0174] The cylinder head 932 defines an intake actuator assembly
port 992I and an exhaust actuator assembly port 992E. The intake
actuator assembly port 992I and the exhaust actuator assembly port
992E can be configured to receive any of the actuator or solenoid
assemblies described herein such that the actuator or solenoid
assemblies can operably engage with an intake valve member (not
shown) or an exhaust valve member (not shown) disposed within the
cylinder head 932, respectively. Similarly, the cylinder head 932
defines an intake return assembly port 993I and an exhaust return
assembly port 993E. The intake return assembly port 993I and the
exhaust return assembly port 993E can be configured to receive any
of the return or spring assemblies described herein such that the
return or spring assemblies can operably engage with the intake
valve member (not shown) or the exhaust valve member (not shown)
disposed within the cylinder head 932, respectively.
[0175] FIGS. 29C and 29D show a top and bottom perspective view,
respectively, of the bottom layer 932C of the cylinder head 932. As
shown, the bottom layer 932C partially defines an intake valve
pocket 938I and an exhaust valve pocket 938E. The bottom layer 932C
includes an intake cylinder bridge 994I and an exhaust cylinder
bridge 994E. The intake cylinder bridge 994I defines a number of
flow passages 948I and the exhaust cylinder bridge 994E defines a
number of flow passages 948E. As shown, the intake valve pocket
938I can be wider than the exhaust valve pocket 938E such that the
intake valve pocket 938I can accommodate a wider valve member than
the exhaust valve pocket 938E. However, in some embodiments, the
intake valve pocket 938I and the exhaust valve pocket 938E can each
be any suitable size and any suitable relative sizes.
[0176] FIGS. 29E and 29F show a top and bottom perspective view,
respectively, of the middle layer 932B. The middle layer 932B
includes a first intake valve pocket upper surface 995I and a first
exhaust valve pocket upper surface 995E. The middle layer 932B also
includes a second intake valve pocket upper surface 999I and a
second exhaust valve pocket upper surface 999E. The intake valve
pocket upper surfaces 995I and 999I and the exhaust valve pocket
upper surfaces 995E and 999E, when the middle layer 932B is in
combination with the bottom layer 932C as shown in FIGS. 29A and
29B, each form a portion of the upper surface of the valve pockets
of the cylinder head 932 and are configured to engage with an
intake valve member and an exhaust valve member disposed within the
valve pockets. The middle layer 932B also defines a first flow
passage 996I and second flow passage 996E. The first flow passage
996I and the second flow passage 996E are configured such that,
when the cylinder head 932 is assembled as shown in FIGS. 29A and
29B, the intake port 937 and the exhaust port 939 are in fluid
communication with the flow passages 948I and 948E via the first
flow passage 996I and the second flow passage 996E,
respectively.
[0177] While the cylinder head 932 is shown and described as
including a top layer, a middle layer, and a bottom layer, in some
embodiments the cylinder head 932 may include any suitable number
of layers. In some embodiments, the cylinder head 932 may include
only two layers such that, for example, the top layer 932A and the
middle layer 932 are formed as a unitary structure.
[0178] FIGS. 30A-30C are various views of an intake valve member
960I. Specifically, FIG. 30A is a perspective view of the intake
valve member 960I, FIG. 30B is a cross-sectional illustration of
the intake valve member 960I, and FIG. 30C is a bottom view of the
intake valve member 960I. The intake valve member 960I can be the
same or similar in structure and/or function to any of the valve
members described herein. For example, the intake valve member 960I
can include a flow passage portion 962I (also referred to as a
valve bridge), a first stem portion 976I, and a second stem portion
977I. The flow passage portion 962I can include a number of sealing
portions 972I and can define a number of flow passages 968I.
Additionally, the intake valve member 960I can include a first
upper wall 998I and a second upper wall 998I. The first upper wall
998I can be configured such that it lies in a plane parallel to a
plane containing a bottom surface 963I of the intake valve member
960I. The second upper wall 997I can be configured such that it is
disposed at an angle relative to the first upper wall 998I and
tapers downward toward the first upper wall 998I. Said another way,
the second upper wall 997I can have a surface lying in a plane that
intersects a surface of the first upper wall at a non-zero angle.
Thus, the first upper wall 998I and the second upper wall 997I can
be configured to engage with a first intake valve pocket upper
surface and a second intake valve pocket upper surface (such as
995I and 999I shown in FIG. 29F) of a cylinder head. Additionally,
the second upper wall 997I can be configured such that the second
upper wall 997I has the same taper angle as the first intake valve
pocket upper surface of a corresponding cylinder head. Said another
way, a valve pocket can have a first valve pocket upper surface and
a second valve pocket upper surface. The first valve pocket upper
surface can lay in a plane parallel to the plane containing the
first upper surface (surface of first upper wall 998I) of the valve
member 960I, the second valve pocket upper surface lying in a plane
parallel to the plane containing the second upper surface (surface
of second upper wall 997I) of the valve member, the second upper
surface of the valve member and the second valve pocket upper
surface configured to be in abutting contact when the valve member
960I is in a closed configuration relative to a cylinder bridge
(e.g., cylinder bridge 994I).
[0179] As shown in FIG. 30C, the intake valve member 960I can have
a first width W1. Additionally, the flow passages 968I can have any
suitable shape or length, and can have the same or similar
characteristics as any of the valve member flow passages described
herein.
[0180] FIGS. 31A-31C are various views of an exhaust valve member
960E. Specifically, FIG. 31A is a perspective view of the exhaust
valve member 960E, FIG. 31B is a cross-sectional illustration of
the exhaust valve member 960E, and FIG. 31C is a bottom view of the
exhaust valve member 960E. The exhaust valve member 960E can be the
same or similar in structure and/or function to any of the valve
members described herein (e.g., intake valve member 960I). For
example, the exhaust valve member 960E can include a flow passage
portion 962E (also referred to as a valve bridge), a first stem
portion 976E, and a second stem portion 977E. The flow passage
portion 962E can include a number of sealing portions 972E and can
define a number of flow passages 968E. Additionally, the exhaust
valve member 960E can include a first upper wall 998E and a second
upper wall 998E. The first upper wall 998E can be configured such
that it lies in a plane parallel to a bottom surface 963E of the
exhaust valve member 960E. The second upper wall 997E can be
configured such that it is disposed at an angle relative to the
first upper wall 998E and tapers downward toward the first upper
wall 998E. Thus, the first upper wall 998E and the second upper
wall 997E can be configured to engage with a first exhaust valve
pocket upper surface and a second exhaust valve pocket upper
surface (such as 995E and 999E shown in FIG. 29F) of a cylinder
head. Additionally, the second upper wall 997E can be configured
such that the second upper wall 997E has the same taper angle as
the first intake valve pocket upper surface of a corresponding
cylinder head.
[0181] As shown in FIG. 31C, the exhaust valve member 960E can have
a second width W2. Additionally, the flow passages 968E can have
any suitable shape or length, and can have the same or similar
characteristics as any of the valve member flow passages described
herein. In some embodiments, the first width W1 of the intake valve
member 960I can be greater than the second width W2 of the exhaust
valve member 960E. In some embodiments, the first width W1 can be
the same width as the second width W2 of the exhaust valve member
960E. In some embodiments, the first width W1 can be less than the
second width W2 of the exhaust valve member 960E.
[0182] FIG. 32 is a partially exploded perspective view of a
cylinder head assembly 1030. The cylinder head assembly 1030 can
include a cylinder head 1032, an intake valve actuator assembly
1080I, an exhaust valve actuator assembly 1080E, an intake valve
return assembly 1020I, and an exhaust valve return assembly 1020E.
The cylinder head 1032 can be the same or similar in structure
and/or function to any of the cylinder heads described herein. For
example, the cylinder head 1032 can define an intake port 1037 and
an exhaust port 1039. Similarly, the intake valve actuator assembly
1080I and/or the exhaust valve actuator assembly 1080E can be the
same or similar in structure and/or function to any of the actuator
or solenoid assemblies described herein. The intake valve return
assembly 1020I and the exhaust valve return assembly 1020E can be
the same or similar in structure and/or function to any of the
return or spring assemblies described herein. The cylinder head
assembly 1030 can be assembled the similarly to any of the cylinder
head assemblies described herein, such as cylinder head assembly
230 as shown in FIG. 7.
[0183] FIG. 33 is a perspective view of a cylinder head assembly
1130 shown without a cylinder head. The assembly 1130 includes an
intake valve actuator assembly 1180I, an exhaust valve actuator
assembly 1180E, an intake valve return assembly 1120I, and an
exhaust valve return assembly 1120E. The assembly 1130 also
includes an intake valve member 1160I and an exhaust valve member
1160E. The intake valve actuator assembly 1180I and/or the exhaust
valve actuator assembly 1180E can be the same or similar in
structure and/or function to any of the actuator or solenoid
assemblies described herein. The intake valve return assembly 1120I
and the exhaust valve return assembly 1120E can be the same or
similar in structure and/or function to any of the return or spring
assemblies described herein. Similarly, the intake valve member
1160I and the exhaust valve member 1160E can be the same or similar
in structure and/or function to any of the valve members described
herein.
[0184] As shown in FIG. 33, the intake valve actuator assembly
1180I and the exhaust valve actuator assembly 1180E can include an
intake actuator spring 1185I and an exhaust actuator spring 1185E,
respectively. Similarly, the intake valve return assembly 1120I and
the exhaust valve return assembly 1120E can include an intake
return spring (not shown) and an exhaust return spring 1122E.
[0185] The intake valve member 1160I and the exhaust valve member
1160E can be coupled to the respective actuator assemblies and
return assemblies via valve guides. For example, a first stem
portion of the intake valve member 1160I can be coupled to a valve
guide 1152I. The valve guide 1152I can be movably disposed in the
cylinder head of the cylinder head assembly 1130. Similarly, a
first stem portion of the exhaust valve member 1160E can be coupled
to a valve guide 1152E, which can also be movable disposed in the
cylinder head of the cylinder head assembly 1130. A second stem
portion of the intake valve member 1160I can be coupled to the
intake valve return assembly 1120I via a valve guide (not shown)
movable disposed within a housing of the intake valve return
assembly 1120I. Similarly, a second stem portion of the exhaust
valve member 1160E can be coupled to a valve guide 1154E. The valve
guide 1154E can be movable disposed within a housing of the exhaust
valve return assembly 1120E. In some embodiments, each of the valve
guides 1152 and 1154 can also provide a seal between, for example,
the valve pocket and the cylinder head.
[0186] FIG. 34 is a cross-sectional view of an engine 1200
according to an embodiment. The engine 1200 can be the same or
similar in structure and function to any of the engines described
herein, such as the engine 800 described above and shown in FIG.
28. FIG. 34 shows the engine 800 with the cross-section taken
through an intake valve member and an intake gas manifold.
[0187] FIGS. 35A and 35B are schematic cross-sectional
illustrations of a valve bridge 1362 and a cylinder bridge 1394 in
a first configuration and a second configuration, respectively. As
shown, the valve bridge 1362 includes three sealing portions 1372.
Between each sealing portion 1372, a flow passage 1368 is defined.
Similarly, the cylinder bridge 1394 includes three sealing portions
1355. Between each sealing portion 1355, a flow passage 1348 is
defined. As shown in FIG. 35A, the valve bridge 1362 and the
cylinder bridge 1394 are in a closed configuration. Each of the
flow passages 1368 of the valve bridge 1362 are obstructed by a
sealing portion 1355 of the cylinder bridge 1394, and each of the
flow passages 1348 of the cylinder bridge 1394 is obstructed by a
sealing portion 1372 of the valve bridge 1362. Thus, in the closed
configuration of FIG. 35A, there is no fluid communication between
the flow passages 1368 and the flow passages 1348.
[0188] Similarly to the valve bridges included in any of the other
valve members described herein, the valve bridge 1362 is configured
to translate along line EE. Thus, for example under the force of
any of the actuator or solenoid assemblies described herein, the
valve bridge 1362 can be translated or shifted relative to the
cylinder bridge 1394 into an open configuration as shown in FIG.
35B. In this configuration, the flow passages 1368 and 1348 are
unobstructed and in fluid communication. As shown in FIG. 35B, when
in the open configuration, the flow passages 1368 and 1348 can be
configured such that the flow passages 1368 of the valve bridge
1362 taper or decrease in diameter as the flow passages 1368
approach the interface between the valve bridge 1362 and the
cylinder bridge 1394. Similarly, the flow passages 1348 can be
configured such that the flow passages 1348 of the cylinder bridge
1394 taper or decrease in diameter as they flow passages 1348
approach the interface between the valve bridge 1362 and the
cylinder bridge 1394.
[0189] FIG. 36 is a schematic cross-sectional exemplary
illustration of the forces applied to a valve member in a closed
configuration relative to a cylinder bridge. As shown, when in a
closed configuration, both the a cylinder bridge and a valve bridge
experience upward forces resulting from gas pressure. When pushed
into the closed configuration and while maintained in the closed
configuration, the tapered portion of the outer wall of the valve
can be pushed against a complementarily tapered interior wall of a
valve pocket. The interior wall of the valve pocket can apply a
resulting downward force that improves the seal between the valve
bridge and the cylinder bridge in the closed configuration.
[0190] FIGS. 37A and 37B are exemplary graphs of the forces and
pressure experienced by a valve member, such as the valve member
shown in FIG. 36 in a closed configuration, at various crank angles
during operation of an engine including the valve member.
[0191] FIGS. 38A and 38B are a perspective view and a partially
exploded view, respectively, of an assembly of according to an
embodiment. As shown, the assembly can include four cylinder head
assemblies, each including an intake valve member and an exhaust
valve member. Each of the cylinder head assemblies can be the same
or similar in structure and/or function to any of the cylinder head
assemblies described herein. Additionally, the engine can include a
housing configured to contain and support each of the actuator
(e.g., solenoid) assemblies for actuating the valve members. Said
another way, the housing can include openings (e.g., eight
openings) such that each opening can contain an actuator assembly
and support the actuator assembly in operable engagement with a
valve member.
[0192] FIGS. 39A-39C illustrate a variety of pistons that can be
configured to be used with any of the engines and/or components
described herein, according to an embodiment. Specifically, the
pistons can be disposed in any of the combustion chambers defined
by the cylinders (e.g., cylinder 103, 803) described herein. In
some embodiments, the combustion chamber and/or piston bowl can be
designed to reduce engine knock tendencies for an engine operating
with one of the valve members described herein. Combustion and CFD
modeling indicate that flow patterns setup by the valve members
described herein can be very different than those in a conventional
engine. As such, unique combustion chamber designs can be used to
move the flame front toward the gases under the exhaust valve
bridge to prevent them from auto-igniting. A piston bowl centered
under the exhaust valve can reduce knock tendency in a port
injected gasoline engine.
[0193] FIG. 39A illustrates a piston 1456 with a flat upper
surface. FIG. 39A illustrates a piston 1556 having a piston boss
1557 and a piston bowl 1558. The piston 1556 can be positioned
relative to any of the cylinder heads described herein such that
the boss, or vertically extending portion, is under the intake side
of the cylinder head and the bowl, or vertically depressed portion,
is under the exhaust side of the cylinder head. FIG. 39C
illustrates a piston 1656 having a piston boss 1657 and a piston
bowl 1658. The piston boss 1657, or vertically extending portion,
has edges extending to the edge of the piston 1656. Additionally,
the piston bowl 1658 is depressed deeper into the piston 1656
compared to the piston bowl 1558 of piston 1556 shown in FIG. 39B.
Similarly to the piston 1565, the piston 1656 can be positioned
relative to any of the cylinder heads described herein such that
the boss, or vertically extending portion, is under the intake side
of the cylinder head and the bowl, or vertically depressed portion,
is under the exhaust side of the cylinder head.
[0194] FIGS. 41A and 41B demonstrate velocity vectors of fluid
traveling through an engine at 20 degrees before top dead center of
any of the engines described herein when using a piston such as the
piston 1565 or the piston 1656 shown in FIGS. 39B and 39C,
respectively. As shown in FIGS. 41A and 41B (which is a close up of
the boxed portion of FIG. 41A), the flow around the spark plug can
be forced downward into a bowl of the piston.
[0195] The following tables (i.e., Table 1 and Table 2) reflect
performance metrics of a cylinder head assembly (such as any of the
cylinder head assemblies described herein), according to an
embodiment.
TABLE-US-00001 TABLE 1 Mean [m/s] Sigma [m/s] Min [m/s] Max [m/s]
Intake Open 1.29 0.15 0.98 1.63 Seating Velocity Intake Close 1.26
0.45 0.98 1.63 Seating Velocity Exhaust Open 1.40 0.08 1.16 1.56
Seating Velocity Exhaust Close 1.39 0.43 0.34 2.47 Seating Velocity
Mean [ms] Sigma [ms] Min [ms] Max [ms] Intake Opening 2.62 0.22
2.15 3.10 Travel Time Intake Closing 2.63 0.03 2.15 3.10 Travel
Time Exhaust Opening 2.42 0.05 2.33 2.54 Travel Time Exhaust
Closing 2.38 0.05 2.24 2.53 Travel Time Mean [deg] Sigma [deg] Min
[deg] Max [deg] Intake Open 371.02 0.88 368.49 372.37 Timing Intake
Close 509.79 0.42 508 79 510.42 Timing Exhaust Open 180.62 0.28
180.04 181.13 Timing Exhaust Close 337.76 0.43 336.92 338.83
Timing
TABLE-US-00002 TABLE 2 Mean [m/s] Sigma [m/s] Min [m/s] Max [m/s]
Intake Open 1.06 0.10 0.80 1.28 Seating Velocity Intake Close 1.32
0.34 0.80 1.28 Seating Velocity Exhaust Open 1.51 0.13 0.97 1.75
Seating Velocity Exhaust Close 1.86 0.52 0.64 3.00 Seating Velocity
Mean [ms] Sigma [ms] Min [ms] Max [ms] Intake Opening 2.65 0.14
2.36 2.95 Travel Time Intake Closing 2.68 0.15 2.36 2.95 Travel
Time Exhaust Opening 2.15 0.17 1.38 2.40 Travel Time Exhaust
Closing 2.44 0.10 2.20 2.60 Travel Time Mean [deg] Sigma [deg] Min
[deg] Max [deg] Intake Open 334.18 0.54 332.97 335.49 Timing Intake
Close 547.83 0.28 547.10 548.26 Timing Exhaust Open 157.52 0.52
156.09 158.44 Timing Exhaust Close 385.26 0.68 383.40 386.62
Timing
[0196] The engines and cylinder head assemblies described herein
can be used for fully variable valvetrain actuation. In other
words, the valve members can be actuated to perform a variety of
valve and/or engine events or processes due to the flexibility of
the actuation assemblies and return assemblies in the cylinder head
assemblies. In some embodiments, for example, an intake valve
member and an exhaust valve member can be actuated independently to
perform various types of engine cycles or engine processes. FIGS.
40A and 40B illustrate examples of various valve actuation cycles
through various crank angles. The cylinder head assemblies
described herein can be actuated as shown by the valve motion
profiles in the graphs illustrated in FIGS. 40A and 40B.
[0197] As shown in FIG. 40A, in some embodiments, a first valve
(e.g., an intake valve member such as any of the valve members
described herein) can be moved to an open position as the crank
angle of a crankshaft associated with a piston within a combustion
chamber associated with the first valve approaches bottom dead
center (BDC). The first valve can be maintained in the open
position, and a second valve (e.g., an exhaust valve member such as
any of the valve members described herein) can be moved to an open
position as the crank angle approaches top dead center (TDC). After
opening the second valve and as the crank angle moves away from TDC
back toward BDC, the first valve can be closed. After the crank
angle reaches BDC, the second valve can be closed. Thus, the first
valve and the second valve can be configured and actuated such that
the first valve and the second valve have overlapping open periods.
Said another way, the first valve and the second valve can both be
maintained in an open position for a period of time. Similarly, the
first valve and the second valve can both be maintained in a closed
position for a period of time. In some embodiments, the first valve
can be reopened for a period after closing the first valve while
maintaining the second valve in the open position.
[0198] With respect to the operation of any of the systems or
assemblies described herein, the timing of an engine incorporating
any of the cylinder head assemblies described herein can be
virtually unlimited with respect to piston position. Additionally,
in some embodiments, the duration of valve events can be limited
only by actuation speed. In some embodiments, the cylinder head
assemblies described herein can translate or moved a valve member
from a neutral or center-biased position to an open position in,
for example, about 2 ms, in about 3 ms, and/or between about 2 ms
and about 3 ms. In some embodiments, the cylinder head assemblies
described herein can translate or moved a valve member from a
neutral or center-biased position to a closed position in about 2
ms, in about 3 ms, and/or between about 2 ms and about 3 ms. In
some embodiments, the cylinder head assemblies described herein can
translate or moved a valve member from an open position to a closed
position or from a closed position to an open position in about 2
ms, in about 3 ms, and/or between about 2 ms and about 3 ms.
[0199] In some embodiments, any of the valve members and/or
cylinder head assemblies can be controlled according to methods or
used in cycles described in U.S. Pat. No. 9,145,797, entitled
"Valve Apparatus for an Internal Combustion Engine," issued Sep.
29, 2015, which is hereby incorporated by reference in its
entirety.
[0200] FIG. 42 is a schematic illustration of a system 1500,
according to an embodiment. As shown in FIG. 42, the system 1500
can include an electronic control unit (ECU) 1510 and a current
driver 1512. In some embodiments, the electronic control unit 1510
can include integrated valve control algorithms. Additionally, the
electronic control unit 1510 can be configured to receive inputs
from engine sensors 1514 and valve position sensors 1516. In some
embodiments, the engine sensors 1514 can sense various conditions
of the engine (such as any of the engines described herein), such
as, for example, pressure and/or temperature in a combustion
chamber. In some embodiments, the valve position sensors 1516 can
sense the position of one or more valve members (such as any of the
valve members described herein) included in the engine (e.g., in a
cylinder head assembly).
[0201] In response to the received inputs, the electronic control
unit 1510 can send signals to engine actuators 1518 associated with
the engine. Additionally, the electronic control unit 1510 can send
signals to the current driver 1512. For example, in some
embodiments, the electronic control unit 1510 can send
transistor-transistor logic (TTL) drive signals to the current
driver 1510. The current driver 1512 can then send drive signals to
a valve actuator 1580. The valve actuator 1580 can be, for example,
any of the actuator or solenoid assemblies described herein. Thus,
the system 1500 can be used to control the operation of any of the
cylinder head assemblies described herein such that the valve
members can be fully variably actuated to complete various engine
cycles.
[0202] FIG. 43 is a schematic illustration of a system 1600,
according to an embodiment. As shown in FIG. 43, the system 1600
can include an electronic control unit (ECU) 1610 and a vehicle
control unit (VCU) 1611. In some embodiments, the system 1600 can
also include a power source 1613. The electronic control unit 1610
can be configured to receive signals from engine sensors 1614 and
to send signals and/or instructions to engine actuators 1618. In
some embodiments, the engine sensors 1614 can sense various
conditions of the engine (such as any of the engines described
herein), such as, for example, pressure and/or temperature in a
combustion chamber. The electronic control unit 1610 can also be
coupled to the vehicle control unit 1611. The vehicle control unit
1611 can received sensor data from a variety of sensors 1617, such
as sensors corresponding to valve position, engine position, and
other data. The vehicle control unit 1611 can send control signals
to each of four distributed current drivers 1615A-1615D. In some
embodiments, the vehicle control unit 1611 can send valve actuator
TTL control signals to the distributed current drivers 1615A-1615D.
Each of the distributed current drivers 1615A-1615D are operable
coupled to an actuator 1680A-1680D. The power source 1613 can also
be coupled to each of the four distributed current drivers
1615A-1615D. Although four distributed current drivers 1615 and
four actuators 1680 are shown, the system 1600 can include any
suitable number of distributed current drivers and actuators. The
actuators 1680 can include any of the actuator or solenoid
assemblies described herein such that the system 1600 can control
the valve member positions of valve members (such as any of the
valve members described here) within any of the cylinder head
assemblies described herein. Thus, the system 1600 can be used to
control the operation of any of the cylinder head assemblies
described herein such that the valve members can be fully variably
actuated to complete various engine cycles.
[0203] FIG. 45 is an illustration of a method 3100 of operating any
of the cylinder head assemblies and/or engines described herein.
The method 3100 includes, at 3102, moving a valve member in a first
direction within a valve pocket defined by a cylinder head from a
first configuration to a second configuration such that a gas
manifold is in fluid communication with a cylinder via a plurality
of valve passages defined by the valve member. At 3104, the valve
member is moved in a second direction opposite the first direction
within the valve pocket from the second configuration to a third
configuration such that the gas manifold is fluidically isolated
from the cylinder. At 3106, the valve member is released such that
the valve member moves to the first configuration.
[0204] FIG. 46 is an illustration of a method 3200 of operating any
of the cylinder head assemblies and/or engines described herein.
The method 3200 includes, at 3202, applying a first current to a
first electromagnetic coil of an actuation assembly such that an
armature is drawn toward the first electromagnetic coil, the
armature being coupled to a valve member such that the movement of
the armature causes the valve member to move within a valve pocket
defined by a cylinder head from a neutral configuration to an open
configuration. The valve member can define a plurality of valve
flow passages. A gas manifold can be in fluidic communication with
a cylinder via the plurality of valve flow passages in the open
configuration. At 3204, the application of the first current to the
first electromagnetic coil can be ceased such that the valve member
moves to the neutral configuration. At 3206, a second current can
be applied to a second electromagnetic coil of an actuation
assembly such that the valve member moves to a closed
configuration, the gas manifold being fluidically isolated from the
cylinder in the closed configuration.
[0205] In some embodiments, the electromagnetic actuators (also
referred to as solenoid assemblies) described herein can include
two nested coils rather than a single wound coil for variability of
control. For example, one of the two coils could be actuated at
various points during valve member motion to achieve the desired
force and reduce power consumption. Additionally, in some
embodiments, square, rectangular, or flat wire can be used for the
coil rather than standard round wire. Thus, tighter packaging may
be achieved while utilizing the same number of turns.
[0206] While various embodiments have been described above, it
should be understood that they have been presented by way of
example only, and not limitation. Where methods described above
indicate certain events occurring in certain order, the ordering of
certain events may be modified. Additionally, certain of the events
may be performed concurrently in a parallel process when possible,
as well as performed sequentially as described above. While the
embodiments have been particularly shown and described, it will be
understood that various changes in form and details may be made.
Although various embodiments have been described as having
particular features and/or combinations of components, other
embodiments are possible having a combination of any features
and/or components from any of embodiments as discussed above.
* * * * *