U.S. patent number 3,915,136 [Application Number 05/504,323] was granted by the patent office on 1975-10-28 for control system for exhaust gas recirculating valve.
This patent grant is currently assigned to Ranco Incorporated. Invention is credited to Roland B. Caldwell.
United States Patent |
3,915,136 |
Caldwell |
October 28, 1975 |
Control system for exhaust gas recirculating valve
Abstract
A pressure operated exhaust gas recirculation control valve in
an internal combustion engine is operated by pressure from the
intake manifold as controlled by a pressure regulator. The
regulator responds to a pressure signal which varies as a function
of the air intake flow rate into the engine. When the throttle is
closed or at an idle position, a controller responsive to the air
pressure at a spark port adjacent the throttle plate prevents the
regulator from opening the exhaust gas recirculation control valve.
The controller also prevents the regulator from opening the exhaust
gas recirculation valve when the engine approaches a wide open
throttle condition irrespective of the intake air flow rate. In one
disclosed embodiment the controller is associated with the
regulator in a single assembly and the controller directly operates
the regulator to prevent exhaust gas recirculation when the engine
idles and as the engine approaches a wide open throttle
condition.
Inventors: |
Caldwell; Roland B.
(Worthington, OH) |
Assignee: |
Ranco Incorporated (Columbus,
OH)
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Family
ID: |
27034363 |
Appl.
No.: |
05/504,323 |
Filed: |
September 9, 1974 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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445628 |
Feb 25, 1974 |
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320151 |
Jan 2, 1973 |
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Current U.S.
Class: |
123/568.29 |
Current CPC
Class: |
F02M
26/56 (20160201) |
Current International
Class: |
F02M
25/07 (20060101); F02M 025/06 () |
Field of
Search: |
;123/119A |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Burns; Wendell E.
Attorney, Agent or Firm: Watts, Hoffmann, Fisher &
Heinke Co.
Parent Case Text
CROSS-REFERENCED APPLICATION
This application is a continuation-in-part of copending U.S. Pat.
application Ser. No. 445,628 filed Feb. 25,1974 by Roland B.
Caldwell, entitled CONTROL SYSTEM FOR EXHAUST GAS RECIRCULATION
VALVE which was, in turn, a continuation-in-part of U.S. Pat.
application Ser. No. 320,151 filed Jan. 2,1973 by Roland B.
Caldwell and entitled CONTROL SYSTEM FOR EXHAUST GAS RECIRCULATION
VALVE, now abandoned.
Claims
What is claimed is:
1. An exhaust gas recirculating system for an engine in which a
fluid pressure operated exhaust gas recirculating valve has an open
condition to enable engine exhaust gas to mix with engine intake
gas and a closed condition, a fluid pressure regulator
communicating valve operating pressure from a pressure source to
the valve in relation to gas flow through the engine and valve
controller means for effecting operation of the valve to the closed
condition and preventing said regulator from communicating
operation pressure to said valve in response to predetermined
engine operating conditions irrespective of the gas flow rate
through the engine.
2. An exhaust gas recirculating system as claimed in claim 1
wherein said valve controller comprises a fluid signal producing
means communicating with engine intake air to produce fluid signals
which vary in magnitude in dependence on engine speed and load and
a controller member movable in response to fluid signals of a
predetermined level to effect closing of said valve.
3. A system as claimed in claim 2 further characterized in that
said signal producing means comprises a port in an engine intake
air duct, a pressure signal transmitting conduit extending from
said port and a movable throttling member in said intake air duct,
said throttling member having a given throttling position in which
said port is communicated with air substantially at atmospheric
pressure and movable from said throttling position to communicate
said port with engine intake manifold pressure, said signal
producing means effecting operation of said valve to the closed
condition when said throttling member is in said throttling
position.
4. A system as claimed in claim 1 wherein said valve controller
comprises a movable member which is positioned to effect closing of
said valve when the engine is idling.
5. A system as claimed in claim 1 wherein said valve controller
comprises a movable member which is positioned to effect closing of
said valve when the engine is operating under substantially wide
open throttle conditions.
6. A system as claimed in claim 1 wherein said fluid pressure
regulator comprises a regulator valve means including a valve body
movable between a first position wherein valve operating pressure
is communicated from said pressure source to said exhaust gas
recirculating valve for opening said valve, a second position
wherein communication from said pressure source to said valve is
blocked and atmospheric air pressure is communicated to said
exhaust gas recirculating valve for closing said valve and a third
position wherein communication of atmospheric air pressure and
valve operating pressure to said valve is blocked so that the
condition of the valve is stabilized, actuator means for
positioning said valve body in response to the flow rate of gas
through the engine to change the condition of said valve in
response to changes in the rate of gas flow through the engine,
said controller means comprising a controller member operable to
move said valve body to said second position when the engine idles
and when the engine operates substantially at a wide open throttle
condition.
7. A system as claimed in claim 6 wherein said controller means
further comprises biasing means for urging said controller member
towards a position in which said valve body is in said second
position.
8. A system as claimed in claim 6 wherein said actuator means
comprises an actuator member for engaging and moving said valve
body, said controller member defining a surface portion engageable
with said actuator member, and said controller means further
comprising force applying means for urging said controller member
into engagement with said actuator member for moving said valve
body to said second position.
9. In an exhaust gas recirculation control system for an internal
combustion engine having an air intake duct containing a movable
throttle, a pressure operated exhaust gas recirculation control
valve openable to permit recirculation of exhaust gas from an
engine exhaust duct to an engine intake duct, pressure source means
providing a source of operating pressure for the valve, a pressure
regulator between said pressure source and said valve for governing
communication of operating pressure between said valve and said
pressure source, signal means providing an input signal to the
regulator which varies in magnitude in relation to gas flow through
the engine, said regulator controlling communication of operating
pressure between said source means and said valve in response to
said input signal, and valve controller means for blocking
communication of operating pressure from said source means to said
valve when the engine is operated at idle speed and at wide open
throttle.
10. A system as claimed in claim 9 wherein said valve controller
means comprises second signal means for producing a fluid pressure
signal which varies in accordance with positioning of the throttle
and engine loading, a pressure operated assembly in communication
with said fluid signal and movable from a first position to a
second position in response to increases in magnitude of the second
signal beyond a predetermined level relative to atmospheric
pressure, said assembly comprising a controller member movable
between a position wherein communication between said pressure
source means and said valve is blocked and said valve is
communicated to pressure which is ineffective to open the valve and
a second position wherein said valve and said pressure source means
are in communication via said regulator.
11. A system as claimed in claim 10 wherein said pressure source
means comprises an engine intake manifold, a pressure reservoir
communicating with said intake manifold and said regulator, and a
check valve between said reservoir and said intake manifold to
enable said reservoir to be charged from said intake manifold and
prevent the charge in said reservoir from being dissipated to said
manifold, said controller member effective to communicate said
valve to atmospheric pressure in said first position while blocking
communication of said reservoir to atmospheric pressure whereby
said reservoir is maintained charged.
12. In an exhaust gas recirculation system for an engine having an
air induction system, an exhaust system, a pressure operated
exhaust gas recirculation control valve for communicating said
induction and exhaust systems, and means defining a source of valve
operating pressure; a control unit for governing operation of said
exhaust gas recirculation control valve comprising:
a. a regulator valve means between said pressure source and said
exhaust gas recirculation valve comprising a valve body movable to
variably govern the communication of pressure from said source to
said exhaust gas recirculation control valve and thereby control
the position of said control valve;
b. pressure responsive actuator means for effecting movement of
said valve body in relation to pressure signal levels which vary
according to the flow rate of gas through the engine; and,
c. controller means cooperatively related with said actuator means
for effecting movement of said valve body to block communication of
pressure from the source to the control valve when the engine idles
and is operated substantially at a wide open throttle
condition.
13. The system claimed in claim 12 wherein said actuator means
comprises a chamber communicable with a fluid signal pressure
source means which varies according to changes in the flow rate of
gas through the engine, and an actuator member supported for
movement in response to changes in said fluid signal pressure to
move said valve body, said controller means comprising a second
chamber communicable with a second fluid signal pressure source
means for producing fluid signals having less than a predetermined
magnitude with respect to atmospheric pressure when the engine
idles and is operated substantially at wide open throttle and a
controller member supported for movement in response to
establishment of fluid pressures in said second chamber less than
said predetermined magnitude, said controller member biased to
engage said actuator member and said valve body to block
communication from said source to said control valve.
14. The system claimed in claim 13 wherein said controller member
is biased to engage said actuator member by first spring means, and
further including second spring means biasing said actuator member
to resiliently oppose movement thereof in response to variations in
pressure signal levels resulting from detected changes in gas flow
rate through the engine.
15. The system claimed in claim 14 further including third spring
means biasing said valve body in opposition to movement thereof by
said actuator member.
16. The system claimed in claim 15 wherein said second and third
spring means are cooperatively related with said actuator member
and said valve body, respectively, in opposition to movement of
said actuator member and said valve body by said controller member,
said first spring means effective to overcome the biasing forces of
said second and third spring means and effective movement of said
valve body to said blocking position when said second fluid
pressure signal source means produces a pressure signal less than
said predetermined magnitude.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to improvements in systems for
controlling the recirculation of exhaust gases through an internal
combustion engine to reduce or eliminate the presence of nitrous
oxide in the engine exhaust gases.
2. The Prior Art
Under certain operating conditions internal combustion engines tend
to produce exhaust gases having undesirably high levels of nitrous
oxide and the prior art has proposed recirculating controlled
quantities of exhaust gas to the engine intakes in order to reduce
or eliminate the presence of nitrous oxides in the exhaust gases. A
vacuum operated exhaust gas recirculation control valve (EGR valve)
and a control system for operating the EGR valve to govern the
recirculation of engine exhaust gas back into an engine manifold is
disclosed in U.S. Pat. No. 3,739,797, issued June 19,1973 to
Caldwell. In that system the vacuum for operating the EGR valve was
furnished by the intake manifold and an associated vacuum reservoir
through a vacuum regulator which regulated the valve operating
vacuum according to the vacuum at a venturi of the engine
carburetor. The regulator was constructed to communicate a valve
operating vacuum level to the EGR valve which varied as a
predetermined multiple, or amplification, of the venturi vacuum
pressure. Thus, the vacuum control signal to the regulator varied
as a function of air flow into the engine and the output of the
vacuum regulator varied as an amplified function of the venturi
vacuum so long as the vacuum level provided by the intake manifold
and vacuum reservoir remained sufficiently great to produce the
amplified valve operating vacuum demanded by the venturi vacuum
level.
When engines idle, the exhaust emissions do not contain sufficient
nitrous oxides to warrant exhaust gas recirculation and exhaust gas
recirculation causes the engine to idle roughly. When engines are
operated at wide open throttle the engine performance is also
adversely affected by recirculation of exhaust gases. To optimize
the performance of engines equipped with exhaust gas recirculation
systems, it has been found desirable to positively close the EGR
valve in response to movement of the throttle both to its wide open
position and to its closed or idle position.
Although exhaust gas recirculation need not occur when an engine
idles it is generally required when the engine is operated at low
speeds above the idle speed. The pressure at the carburetor venturi
is essentially atmospheric pressure when the engine idles because
the throttle is substantially closed, and when the engine operates
at relatively low speeds the venturi vacuum level increases only
slightly from atmospheric pressure because of the relatively low
flow rates of air through the carburetor.
In order to assure exhaust gas recirculation at low engine speeds
it was sometimes desirable to preset the regulator to provide an
initial, low level, valve operating pressure output when there was
no venturi vacuum input pressure to the regulator, i.e. when the
throttle was closed. The preset pressure output level was
controlled so that it was just insufficient to open the EGR valve
in the absence of a venturi vacuum signal. While presetting the
regulator tended to assure that sufficient regulator output
pressure for opening the EGR valve was available at low level
venturi vacuums, the EGR valve was not positively closed when the
engine idled and under certain circumstances could remain slightly
open during idling, particularly if the initial regulator valve
operating output was excessive and/or when replacement parts for
the vehicle caused changes in engine operating parameters, e.g.
when a replacement muffler or exhaust system caused increased
exhaust gas back pressures which tended to open the EGR valve. This
caused the engines to idle poorly.
As noted above, some EGR valve controlling sytems have employed a
vacuum reservoir which was connected between the regulator and the
intake manifold so that when the manifold vacuum levels were
reduced, the reservoir maintained a relatively large vacuum level
for operating the EGR valve via the regulator. These systems thus
enabled the EGR valve to remain substantially wide open even though
an associated engine was operated for sustained periods under
relatively heavy loads at cruising speeds (e.g. when an automobile
towing a trailer encountered a long grade). Under these conditions
the intake manifold vacuum is reduced to a relatively low magnitude
because the throttle is opened substantially but relatively high
exhaust gas recirculation flow rates are necessary and, the intake
manifold vacuum level itself may not be great enough to open the
EGR valve as fully as necessary to provide the required amount of
exhaust gas recirculation. The vacuum reservoir provided the
necessary pressure to position the EGR valve to provide desirable
flow rates of recirculating exhaust gas.
Some of these systems were constructed to "dump" the vacuum
reservoir (i.e., the reservoir was vented to the vacuum level in
the intake manifold) when the throttle approached its wide open
position in order to enable the EGR valve to close. It should be
noted that when the wide open throttle position is approached the
intake air flow rates increase towards maximum and the venturi
signal to the regulator is maximized. Accordingly the regulator is
conditioned to transmit all of the available valve operating
pressure from the intake manifold and reservoir to the EGR valve
when the throttle is at or substantially at its wide open position.
Under these circumstances, even when the reservoir is dumped, low
magnitude vacuum pressures are transmitted to the EGR valve and the
combination of the low level valve operating pressures and the
exhaust gas back pressure acting on the EGR valve tends to prevent
the EGR valve from positively closing. Hence some EGR flow may
occur which adversely affects the engine performances at wide open
throttle.
Moreover, in some systems relatively large volume reservoirs were
employed to enable EGR flows during sustained periods of engine
operation near wide open throttle and dumping the large volume
reservoirs was undesirable because the reservoir had to be
recharged after each dump, and until recharged the reservoir could
not always adequately perform its function.
While systems constructed according to the patent referred to were
extremely effective in reducing nitrous oxide emissions, since the
EGR valve was not always positively closed at wide open throttle
conditions and at engine idle speeds the engine performance was not
always optimized since some exhaust gas recirculation, under the
noted circumstances, could occur.
SUMMARY OF THE INVENTION
According to the present invention a pressure operated EGR valve is
associated with a regulator which governs the communication of EGR
valve operating pressure to the EGR valve from an operating
pressure source as a function of the flow rate of gas through the
engine, and an EGR valve controller functions to effect positive
closing of the EGR valve irrespective of the flow rate of gas
through the engine when the engine idles and when the engine
operates at or substantially at wide open throttle.
In preferred embodiments of the invention the EGR valve operating
pressure source is provided by an engine intake manifold and an
associated vacuum pressure reservoir. Carburetor venturi vacuum
levels are transmitted to the regulator to provide regulator input
signals which vary as a function of gas flow rates through the
engine. The EGR valve is supplied with vacuum pressure from the
regulator to open the EGR valve, while venting the EGR valve to
atmospheric pressure closes the EGR valve.
According to the preferred embodiment, the EGR valve controller
operates in response to pressure levels at a "spark port" located
adjacent a throttle plate in the engine carburetor. When the
throttle is closed, or at idle position, the spark port is exposed
to atmospheric pressure or, at most, a small magnitude vacuum
pressure, and the EGR valve controller functions to prevent the
regulator from communicating EGR valve opening pressure to the EGR
valve and to condition the EGR valve for positive closing (i.e. by
venting the EGR valve to atmospheric pressure). This feature of the
invention enables the regulator to be preset to any desirable
output pressure level in the absence of a carburetor venturi signal
because the EGR valve is positively closed when the engine idles
regardless of the theoretical regulator output pressure at idle
speed.
When the throttle is partly opened during normal operation of the
engine the spark port is exposed to the engine intake manifold
pressure and the valve controller is rendered ineffective to govern
operation of the EGR valve. When the throttle moves from the engine
idle position the spark port is abruptly communicated with the
intake manifold pressure and the controller is therefore abruptly
rendered ineffective. This permits the regulator to be preset and
conditioned to provide for substantial EGR valve operating output
pressures to the EGR valve at low engine speeds above the idle
speed (low level venturi vacuums) without risk of the EGR valve
opening when the engine idles.
When the throttle is at, or substantially at, its wide open
position the magnitude of the intake manifold pressure approaches
atmospheric pressure and at a predetermined, desired intake
manifold pressure the valve controller again operates to prevent
the regulator from supplying operating pressure for opening the EGR
valve irrespective of the relatively high level of the input
venturi vacuum signal to the regulator. The EGR valve thus tends to
positively close regardless of the exhaust gas back pressure.
Because the EGR valve controller operates to vent the EGR valve to
atmospheric pressure while blocking the transmission of operating
pressure from the regulator to the EGR valve, the pressure level in
the vacuum reservoir associated with the intake manifold and the
regulator is not substantially depleted, or "dumped," when the
engine is operated at wide open throttle. The new system thus
permits the reservoir to remain charged during wide open throttle
operation of the engine and substantial recharging is not
required.
An important object of the present invention is the provision of an
EGR valve controlling system wherein a pressure operated EGR valve
is controlled by a pressure regulator as a function of the flow
rate of gas through the engine and in which an EGR valve controller
effects closing of the EGR valve when the throttle is at its idle
and its wide open positions irrespective of the flow rate of gas
through the engine.
Other objects and advantages of the invention will be apparent from
the following description of preferred embodiments of the invention
made in reference to the accompanying drawings which form part of
the specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary schematic view of an internal combustion
engine and an exhaust gas recirculating valve and a control system
therefore embodying the invention; and,
FIG. 2 is a cross-sectional view showing an altrnate construction
of part of the EGR valve control system.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 of the drawings, an internal combustion engine,
only partly illustrated, includes a suitable or conventional
carburetor 10 having a throttle plate 11 and a venturi 12; an
intake manifold 13, and, an exhaust manifold 15. An exhaust gas
recirculation (EGR) control valve 14 is provided for controlling
the passage of exhaust gases from the exhaust manifold 15 to the
intake manifold 13 for recirculation through the engine.
The EGR valve 14 is preferably fluid operated and is operated from
a source of vacuum pressure provided by the intake manifold 13 and
an associated vacuum reservoir 13a. Operation of the EGR valve 14
is governed by a pressure regulator 26 and by a valve controller 34
which are disposed between the EGR valve and the operating pressure
source. When the throttle 11 is closed or at its idle position, as
well as substantially at its wide open throttle position, the
controller 34 prevents the EGR valve from opening. During other
operating conditions of the engine the EGR valve is opened and
controlled as a function of gas flow rate through the engine by the
regulator 26.
The EGR valve 14, which is schematically shown, comprises a housing
16 divided by a plate 17 into upper and lower chambers 20, 21. The
upper chamber 20 is divided into upper and lower chamber portions
20a, 20b, by a flexible diaphragm 18. The lower chamber 21 has an
inlet port 22 communicating with the exhaust manifold 15, and an
outlet port 23 communicating with the intake manifold. A valve
member 24 is connected to the diaphragm 18 by a stem which extends
through a conforming opening in the plate 17 and is moved by
deflections of the diaphragm to close and open the port 22. A
spring 25 normally urges the valve member 24 to close the port 22.
The valve member 24 is moved from the port 22 when the vacuum
pressure level in the upper chamber portion 20a is sufficient to
raise the valve member 24 against the force of the spring 25. The
lower chamber portion 20b is provided with a port 28 which vents
the chamber portion 20b to atmospheric pressure. This permits the
diaphragm 18 to flex in accordance with the vacuum level in the
chamber 20a with respect to the plate 17.
Valve opening vacuum pressure is communicated to the upper chamber
portion 20a from the intake manifold 13 and the reservoir 13a
through the regulator 26. A conduit 27 communicates the manifold 13
and reservoir 13a to an inlet port 30 of the vacuum regulator 26, a
chamber 32 of the vacuum regulator, a conduit 33 from the chamber
32 to the valve controller 34, and a conduit 35 from the controller
34 to the chamber 20 of the valve 14.
The output of the vacuum regulator 26, which is communicated to the
conduit 33, is controlled according to the vacuum pressure at the
venturi 12 of the carburetor 10 which is communicated to the
regulator 26 via a conduit 36. The vacuum at the venturi 12 is
created by the flow of engine intake air through the venturi,
varies as a function of the flow rate of air entering the engine
and is generally of small magnitude compared to the vacuum in the
intake manifold and the reservoir. The venturi vacuum pressure
applied to the regulator is effective to regulate the communication
of valve operating vacuum to the regulator output conduit 33 to
provide a valve operating vacuum in the chamber 20a which varies as
an amplified function of the vacuum at the venturi, provided a
sufficiently great valve operating vacuum is available from the
intake manifold and the reservoir.
The level of the vacuum pressure produced in the regulator output
chamber 32 is thus controlled by the level of vacuum pressure
communicated to a chamber 40 of the regulator 26 from the
carburetor venturi 12 to the extent sufficient source vacuum
pressure is available. One wall of the chamber 40 is formed by a
flexible diaphragm 41 which is laterally moved in the chamber 40 in
relation to the level of venturi vacuum in the chamber.
Lateral movement of the diaphragm 41 is transmitted to a diaphragm
valve 42 by a link 43. The volume between the diaphragm 41 and the
diaphragm valve 42 is open to atmosphere so that as the vacuum in
the chamber 40 increases in magnitude, the diaphragm 41 is
deflected upwardly, as viewed in the drawing. When the magnitude of
the venturi vacuum in the chamber 40 is reduced relative to
atmospheric pressure, indicating a reduction in the air flow rate
into the engine, the diaphragm 41 tends to move downwardly as
viewed in the drawing.
Upward movement of the diaphragm valve 42 by the diaphragm 41 tends
to communicate the chamber 32 with the conduit 27 to increase the
vacuum at the output conduit 33. Downward movement of the diaphragm
valve 42 by the diaphragm 41 tends to communicate the output
conduit 33 with atmospheric pressure present in the casing between
the diaphragm 41 and the valve 42 to reduce the vacuum at the
output 33.
The relative areas of the diaphragm 41 and the diaphragm valve 42
determine the amplification ratio of the regulator. If the pressure
area of the diaphragm 41 is extremely large compared to the
pressure area of the diaphragm valve 42 the pressure amplification
provided by the regulator is great. When the vacuum pressure in the
chamber 32 approximates a predetermined multiple of the magnitude
of the vacuum in the chamber 40, the forces acting on the diaphragm
41 and the valve 42 are balanced and the diaphragm valve is
positioned to seal the chamber 32 from the conduit 27 and
atmospheric air pressure and thus provide an output vacuum in the
conduit 33 substantially corresponding to a given multiple of the
vacuum in the chamber 40.
In the illustrated embodiment of the invention, a light tension
spring 44 is disposed above the diaghragm 41 to bias the diaphragm
upwardly when no venturi signal is present in the chamber 40. The
spring 44 thus establishes a preset, or predetermined, initial
vacuum pressure output from the regulator 26. As the air flow rate
through the carburetor venturi increases, the vacuum in the chamber
40 increases causing the regulator output vacuum level to increase
from the initial output level as an amplified function of the
increase in venturi vacuum. Thus when the venturi vacuum level
reaches a predetermined level, for example when the engine is
operating at a low cruising speed, adequate power for opening the
EGR valve 14 from the regulator output is assured
For a more detailed description of the vacuum regulator 26,
reference is made to the disclosures in my copending U.S. Pat.
application Ser. No. 202,783, now U.S. Pat. No. 3,739,797 and to
U.S. Pat. No. 3,125,111.
As mentioned previously, when the carburetor throttle plate 11 is
at idle (as shown in the drawing), in which case the throttle plate
substantially closes the intake, it is desirable to close the EGR
valve 14 to prevent recirculation of exhaust gases. Because of the
initial low level vacuum output from the regulator 26, the EGR
valve may tend to open slightly when the engine idles and the
consequent recirculation of exhaust gas is undesirable.
Likewise, when the engine operates at wide open throttle, exhaust
gas recirculation is not desirable, and the valve 14 should be
closed notwithstanding the large magnitude venturi vacuum signal
provided to the regulator which would theoretically maintain the
valve wide open. Where the reservoir 13a is relatively lage, the
valve 14 would tend to remain open at the wide open throttle
condition of the engine until the vacuum in the reservoir 13a is
dissipated, for example, by slow leakage of atmospheric air into
the reservoir via elements of the system.
The controller 34 is effective to close the EGR valve and to
prevent communication of valve operating pressure to the valve via
the regulator 26 when the engine idles as well as when the engine
operates at wide open throttle. The controller 34 is schematically
shown and comprises a casing 45 supporting a rigid transverse
internal wall 46 and a transverse diaphragm 47. The wall 46 and the
diaphragm 47 are spaced apart to define chambers 50, 51, 52 within
the casing. The chamber 50 communicates with the EGR valve chamber
20a via the conduit 35 and is provided with a first port 53 formed
by a stem 54 of the conduit 33 which projects into the chamber 50
and a second port 55 formed in the chamber wall 46 for
communicating the chamber 50 with the chamber 51. The chamber 51 is
opened to atmosphere by a port 60 in the casing wall.
A valve member 56 is disposed in the chamber 50 and is shiftable
between the ports 53, 55 to close one port while opening the other.
The valve member 56 is connected to the diaphragm 47 by a valve
stem 57 which extends between the valve member and the diaphragm
through the port 55. When the diaphragm 47 flexes towards the
chamber 50 the valve member 56 closes the chamber port 53 and opens
the port 55 to communicate the EGR valve chamber 20a to atmospheric
air pressure via the port 60, the chamber 51 and the port 55. The
EGR valve is thus closed regardless of the output vacuum pressure
level established by the regulator, and the communication of
operating pressure to the valve via the regulator is blocked. When
the diaphragm 47 flexes in a direction away from the chamber 50 the
valve member 56 closes the port 55 and opens the port 53
communicating the EGR valve chamber 20a to the regulator 26. The
EGR valve is then controlled according to the output of the
regulator 26.
Operation of the valve member 56 is governed by a fluid pressure
signal which varies according to engine operating conditions. In
the illustrated embodiment of the invention, the valve member 56 is
biased toward closing on the port 53 by a compression spring 61
between the lower end wall of the chamber 52 and the diaphragm. The
chamber 52 is connected by a conduit 62 with the area of the
carburetor intake immediately adjacent and above the throttle plate
11 when the throttle is closed. The conduit 62 is communicated to
an opening referred to as a "spark port" 63 formed in the wall of
the carburetor.
The pressure at the spark port 63 varies according to engine
operating conditions and is transmitted to the controller chamber
52 to govern movement of the valve member 56. When the engine is
idling the throttle plate is substantially closed and the spark
port is exposed to air substantially at atmospheric pressure
because a portion of the spark port opens upstream from the
throttle plate. The pressure in the chamber 52 is thus about an
atmospheric pressure and the spring 61 forces the valve member 56
to close on the port 53. The force of the valve controller spring
61 is such that when a slight vacuum, e.g. 2 inches Hg. or less, is
established adjacent the spark port 63 the spring 61 moves the
diaphragm 47 so that the valve member 56 opens the port 55, closes
the port 53 and vents the EGR valve chamber 20a to atmospheric air
pressure to close the EGR valve.
Hence when the engine idles the valve member 56 blocks
communication between the regulator 26 and the EGR valve 14 so that
no matter what the preset initial regulator output pressure is, it
is not communicated to the EGR valve. The EGR valve 14 is thus
positively closed when the engine idles.
When the engine speed is increased from idle speed the controller
34 immediately enables the regulator 26 to control positioning of
the EGR valve. As the throttle plate is moved from the idle
position the spark port 63 is abruptly exposed to air which is
substantially at the intake manifold pressure. The pressure in the
controller chamber 52 abruptly changes to about the vacuum level in
the intake manifold, which is greater than 2 inches Hg., and the
atmospheric pressure in the chamber 51 above the diaphragm 47
forces the diaphragm to compress the spring 61, opening the valve
port 53 and closing the port 55. The EGR valve chamber 20a is then
placed in communication with the outlet of the regulator 26 through
the conduit 35, chamber 50, port 53 and the conduit 33. The EGR
valve is thus positioned according to the carburetor venturi vacuum
level via the regulator 26.
When the engine is operated at wide open throttle, either at high
speed or under extreme load, the pressure in the intake manifold
approaches atmospheric pressure and the spark port 63 is exposed to
intake air substantially at that pressure level. Accordingly the
pressure in the chamber 52 again approaches atmospheric pressure
and the spring 61 again urges the valve member 56 into closing
engagement with the port 53 to block the regulator output and
positively close the EGR valve.
It should be noted that at high engine speeds and/or loads when the
port 53 is blocked, the only forces tending to open the EGR valve
14 are the forces exerted on the valve member 24 by the exhaust gas
back pressure and the relatively low magnitude intake manifold
vacuum in the chamber 21. The spring 25 produces sufficient force
for maintaining the valve 24 positively closed on the port 53.
The abrupt increase in detected vacuum pressure at the spark port
63 which occurs when the throttle is opened from its idle position
causes a snap motion of the valve member 56 from the port 53 to the
port 55. This minimizes the flow of atmospheric air to the
regulator from the port 55 as the valve member moves between the
ports 53, 55. When the engine approaches the wide open throttle
position the valve member 56 also tends to snap move to close on
the port 53 due to the differential pressure forces acting on the
valve member 56 itself. If desired, the diaphragm 47 and/or the
spring 61 can be suitably constructed to provide for snap motion of
the valve member 56 in both directions of movement without
departing from the invention.
When the engine is operating under load at less than maximum speed
with the throttle plate not fully opened, the intake manifold
pressure can approach atmospheric pressure. In these circumstances
it is desirable to maintain the EGR valve open and the power
necessary for maintaining the valve in an open position dictated by
the venturi vacuum may not be available directly from the intake
manifold. In such circumstances the reservoir 13a supplies the EGR
valve operating power.
The vacuum resrvoir 13a and an associated check valve 72 are
connected in the system to communicate with the intake manifold 13
and the regulator 26. The check valve 72 is connected between the
reservoir and intake manifold to permit evacuation of the reservoir
by the intake manifold while preventing the reservoir from venting
to the intake manifold when the intake manifold vacuum is less than
the reservoir vacuum.
When the throttle is moved toward its wide open position
sufficiently to create an intake manifold vacuum of, for example, 2
inches Hg or less, the controller 34 functions to block the output
from the regulator 26 while venting the chamber 20a of the EGR
valve. Thus the controller 34 functions to prevent the reservoir
13a from being vented to atmosphere along with the EGR valve, and
the reservoir maintains a supply of EGR valve operating power while
the engine is operated at wide open throttle. If the throttle is
then moved gradually closed from its wide open position the
reservoir 13a is capable of providing sufficient vacuum power for
reopening the EGR valve when the controller has operated to
communicate the regulator output to the EGR valve.
Referring now to FIG. 2, an alternate preferred construction of
part of an EGR valve controlling system embodying the present
invention is illustrated in which a regulator and a coacting valve
controller are combined in a single EGR valve controlling unit
indicted by the reference character 100. The unit 100 is associated
with system components which are identical to those illustrated and
described in reference to FIG. 1 and such components are
schematically illustrated and referred to by corresponding
reference characters in FIG. 2. The unit 100 comprises an EGR valve
controlling regulator assembly 101 for governing communication of
operating pressure to an EGR valve 14 and a controller assembly 102
cooperatively related to the regulator assembly 101 for overriding
the normal regulator operation and preventing the regulator from
communicating operating pressure to the EGR valve 14 under
predetermined engine operating conditions. The unit 100 preferably
includes cup-like housing members 104, 106 each formed of a
relatively rigid molded plastic material which are assembled
together by suitable screws to define a generally cylindrical
internal chamber 108 in which the regulator and controller
assemblies are supported.
The regulator assembly 101 normally functions to control the level
of the EGR valve operating pressure supplied to the EGR valve 14 in
response to the mass flow rate of gas through the engine, as
indicated by the level of the carburetor venturi vacuum, and
comprises a diaphragm valve assembly 110 and a valve actuator 111.
The valve assembly 110 is normally operated by the actuator 111 to
provide a controlled EGR valve operating output pressure to the EGR
valve via an output chamber portion 108a which is communicable by
the valve assembly 110 to a source of EGR valve operating pressure
or to an atmospheric air pressure chamber portion 108b. The
position of the EGR valving member is thus modulatable between its
fully open and its closed positions according to operation of the
valve assembly 110 and the actuator 111.
The output chamber 108a communicates with the EGR valve 14 via an
output passage 114 formed by the housing member 106 and the conduit
35. As in the embodiment of the invention illustrated in FIG. 1,
the source of EGR valve operating pressure is provided by the
intake manifold 13 and the associated vacuum reservoir 13a which
are communicated to the chamber portion 108a via an input port 115
formed by the projecting end of the input pressure tube 116 which
is fixed in the housing member 106. The tube 116 and port 115
communicate with the intake manifold and reservoir via an input
pressure passage 118, formed in the housing member 106, and the
conduit 27.
The atmospheric air pressure chamber portion 108b communicates with
the atmospheric air via a vent port 120 defined in the base of the
housing member 106. A suitable air filter (not shown) is supported
in the housing member 106 between the vent port 120 and the chamber
portion 108b.
The diaphragm valve assembly 110 comprises a generally annular
valve body 122 which is supported in the housing member 106 by an
annular, air impervious rubber-like diaphragm member 124 and biased
away from the chamber portion 108a by a valve spring 125. The
diaphragm member 124 forms an air impervious sealed flexible wall
which extends from the valve body 122 to the housing member 106
between the chamber portions 108a, 108b and comprises an inner
annular sealing flange 126 sealingly engaged about the valve body
122, an outer sealing flange 128 seated on and sealingly engaged
with the housing member 106 and a freely flexible wall section 130
disposed between the inner and outer flanges. The diaphragm member
thus prevents communication between the chamber portions 108a, 108b
about the valve body 122 while enabling the valve body to freely
move toward and away from the respective chamber portions 108a,
108b.
The diaphragm member 124 is fixed against the housing member 106 by
an annular retainer ring 132 which defines a radially inwardly
projecting lip 133 which functions to limit the movement of the
valve body 122 away from the chamber portion 108a.
The valve body 122 defines a generally circular base surface 134
facing the chamber portion 108a, an annular spring retaining land
136 projecting from the base 134 for retaining the valve spring 125
in alignment with the surface 134, an annular bearing face 138
engageable with the valve actuator 111, a pair of guide lugs 140
projecting from the bearing face 138 for maintaining the actuator
111 and valve body 122 aligned, a cylindrical through bore 142
extending between the chamber portions 108a, 108b concentric with
and spaced from the tube 116, and a valve seat 144 defined about
the end of the bore 142 opening at the chamber 108b.
A valving member 146 extends across and is resiliently engaged with
the valve seat 144. In the preferred and illustrated embodiment of
the invention, the valving member 146 is defined by a strap or
tongue integral with the diaphragm member 124 and which extends
from the inner sealing flange 126 across the valve body 122 between
the lugs 140. In the condition of the regulator valve assembly 110
illustrated in FIG. 2, the valve body 122 is positioned so that the
valving member 146 is sealingly engaged with the valve seat 144 as
well as being seated on the pressure input port 115 to block
pressure communication between the output chamber portion 108a and
both the atmospheric air pressure chamber portion 108b and the
input pressure passage 118.
When the valve body 122 is moved toward the chamber portion 108b
relative to the tube 116, the valving member 146 remains sealingly
engaged with the valve seat 144 but is disengaged from the port 115
to communicate the passage 118 to the output pressure chamber
portion 108a thus increasing the level of the EGR valve operating
pressure in the chamber portion 108a. When the valve body 122 moves
toward the chamber portion 108a relative to the tube 116 the
valving member 146 engages and seals the port 115 and is disengaged
from the valve seat 144 to communicate the atmospheric air pressure
chamber 108b with the output chamber 108a thus reducing the level
of the valve operating vacuum provided in the output chamber
portion 108a. Movement of the valve body toward the chamber portion
108a is limited by engagement between an abutment projection 148 in
the chamber portion 108a and the base surface 134.
The actuator 111 normally bears on the valve body 122 and effects
movement of the valve body to alter the pressure in the output
chamber portion 108a, in accordance with the vacuum pressure level
at the carburetor venturi. The actuator 111 preferably comprises an
actuator body formed by a generally disc-like imperforate rigid
plastic member 150 which is supported within the chamber 108 by an
air impervious rubber-like annular actuator diaphragm member 152.
The diaphragm member 152 comprises an inner sealing flange 154
which is tightly disposed about and sealed against the actuator
member 150, an outer sealing flange 156 which is seated on and
sealed against the housing member 106 and an intermediate flexible
wall portion 158 extending between the flanges. The actuator member
150 and diaphragm 152 extend completely across the chamber 108 and
form a flexible upper chamber wall of the chamber 108b. The
actuator member 150 defines a central cup-like hub 160 having a
projecting annular bearing face 162 which is engageable with the
valve body bearing face 138. The lugs 140 extend into the hub 160
to guide the bearing face 162 into engagement with the face 138 in
the event of relative movement between the valve body 122 and the
actuator member 150.
The actuator 111 is effective to position the valve body 122 to
control the pressure in the output chamber portion 108a in response
to an input pressure signal provided from the carburetor venturi.
Accordingly an input pressure chamber portion 108c is defined
within the unit 100 above the actuator 111 and which communicates
with the carburetor venturi via a signal passage 164 defined by the
housing member 104 and the conduit 36. As the level of the
carburetor venturi vacuum increases relative to atmospheric
pressure the actuator 111 tends to shift away from the chamber
portion 108b, while reductions in the magnitude of the carburetor
venturi vacuum result in a tendency for the actuator to shift
toward the chamber portion 108b. The valve spring 125 urges the
valve body against the actuator 111 so that the valve body follows
movement of the actuator 111 away from the chamber 108b. When the
actuator 111 moves towards the chamber 108b the valve spring 125 is
compressed by the valve body 122.
The positions of the diaphragm valve 110 and the actuator 111 are
governed by coacting spring and pressure forces. The actuator
member 150 is biased toward the chamber portion 108b by a helical
actuator spring 170 disposed in the chamber portion 108c. The force
exerted on the actuator member 150 by the actuator spring 170 is
opposed by the force exerted by the valve spring 125 on the valve
body 122.
In addition to the spring forces operating on the actuator member
150 and the valve body 122, differential pressure forces are
applied to these respective components to enable the establishment
of a preset, initial regulator output pressure level in the chamber
portion 108a as well as to enable the output pressure level to vary
as an amplified function of the input pressure in the signal
pressure chamber portion 108c throughout a predetermined range of
input signal levels. The differential between the output vacuum
pressure in the chamber 108a and the atmospheric pressure in the
chamber 108b creates a differential pressure force which urges the
valve body 122 toward the chamber portion 108a in opposition to the
force of the valve spring 125.
Assuming that the engine is operating above its idling speed (i.e.,
the EGR valve controller 102 is ineffective) but the venturi vacuum
level is substantially at atmospheric pressure, the actuator member
150 and the valve body 122 are acted on by the opposed springs 125
and 170, with the valve spring 125 being effective to shift the
valve body 122 towards the chamber portion 108b to open the input
pressure port 115 and increase the magnitude of the vacuum output
pressure in the chamber portion 108a. The output chamber pressure
is stabilized at a predetermined level when the differential
pressure force applied to the valve body 122 balances the opposed
spring forces and the valve body is positioned as illustrated by
FIG. 2 with the valving member 146 seated on both the port 115 and
the valve seat 144.
AS the throttle plate is opened further, the level of the vacuum
pressure in the signal input chamber 108c increases from
atmospheric pressure resulting in pressure increases in the output
chamber 108a from the initial pressure level which correspond to a
predetermined multiple of the change in the input signal pressure.
The increase in the venturi vacuum level creates a differential
pressure between the chamber portions 108b, 108c resulting in a
pressure force being exerted on the actuator mamber 150 in
opposition to the actuator spring 170. The resulting unbalanced
force enables the spring 125 to shift the valve body 122 towards
the chamber 108b thus opening the port 115 to the chamber portion
108a while the valving member 146 remains engaged on the valve seat
144.
The pressure amplification ratio between the pressure input signal
and the output chamber pressure level is determined by the ratio of
the areas of the actuator 111 and the diaphragm valve 110. In the
preferred embodiment, the pressure area of the actuator assembly
111 (i.e. the combined area of the actuator member 150 and the
diaphragm 152 exposed to the chamber portion 108c) is about 10
times the effective pressure area of the diaphragm valve 110 (i.e.
the combined area of the valve body 122 and the diaphragm 124
exposed to the chamber portion 108a). Therefore the amplification
ratio of the regulator is 10:1 and for every incremental pressure
change in the chamber portion 108c, the magnitude of the pressure
level in the output chamber portion 108a is changed by an amount
equal to 10 times the incremental signal pressure change.
When the magnitude of the pressure in the chamber 108c reaches a
predetermined level the EGR valve is wide open and the regulator
output pressure chamber 108a remains communicated to the reservoir
13a. The regulator output is therefore at a maximum and no further
increases in EGR valve operating pressure can be furnished as a
direct result of further increases in the input signal level. As
noted previously, the retainer ring flange 133 limits movement of
the valve body 122 towards the chamber portion 108b. When the input
signal chamber pressure level has reached a predetermined magnitude
the output pressure from the regulator 101 is maximum and the valve
spring 125 maintains the valve body 122 at the limit position
established by the flange 133. Accordingly, further increases in
the input signal level cause the actuator member 150 to move from
bearing engagement with the valve body 122 and the lugs 140
maintain the valve body 122 and the member 150 aligned for proper
re-engagement.
When the flow rate of gas through the engine is reduced, as
evidenced by the magnitude of the venturi vacuum being reduced, the
pressure forces acting on the diaphragm valve 110 and the actuator
111 become unbalanced causing the valve body 122 to shift toward
the chamber portion 108a so that the valving member 146 closes the
port 115 and is disengaged from the seat 144. Pressure from the
chamber portion 108b is thus communicated to the chamber portion
108a to reduce the magnitude of the pressure in the chamber 108a
which in turn causes the EGR valve to opeate toward its closed
condition. When the reduction in magnitude of the pressure in the
chamber portion 108a is 10 times the reduction in magnitude of the
venturi vacuum signal the pressure forces acting on the valve 110
and the actuator 111 are again balanced and the pressure level in
the chamber portion 108a is stabilized since the valving member 146
engages both the seat 144 and the port 115.
The controller assembly 102 is disposed in the chamber 108 between
the chamber portion 108c and end wall 180 of the housing member 104
remote from the valve assembly 101, and is effective to override
the actuator 111 for preventing the regulator valve assembly 110
from providing an EGR valve operating output pressure when the
engine idles as well as when the engine is operated substantially
at wide open throttle. The controller assembly 102 cooperates with
the regulator valve assembly 110 so that the vacuum reservoir is
isolated from atmospheric pressure when the controller assembly
operates and the charge in the reservoir 13a is therefore
maintained at all times during operation of the controller
assembly.
In the preferred embodiment of the invention the controller
assembly 102 is operable in response to spark port pressure levels
which are established when the engine idles and when the engine is
operated substantially at wide open throttle, and is ineffective at
all other times during operation of the engine. The assembly 102
forms an air impervious upper wall of the chamber portion 108c and
defines, with the housing member 104, a spark port pressure chamber
portion 108d at the end of the chamber 108 remote from the valve
assembly 110. The pressure at the spark port 63 is communicated to
the chamber portion 108d via the conduit 62 and a passage 182
formed in the housing member 104.
The assembly 102 preferably comprises an operating member 186, a
diaphragm 188 supporting the member 186 for movement towards and
away from the housing end wall 180, a controller spring 190 urging
the member 186 towards the valve assembly 110, and an adjustable
stop mechanism 192 for limiting motion of the member 186 towards
the housing end wall 180. The member 186 is preferably a rigid
disc-like member which is constructed to provide a fixed wall of
the chamber portion 108c when the engine is operated between its
idle speed and its substantially wide open throttle conditions. The
side of the member 186 facing the chamber portion 108c defines an
annular seat 194 for the actuator spring 170 and an annular
abutment 196 which projects towards the actuator member 150 for
limiting relative movement of the actuator member 150 and the
controller member 186 towards each other. The side of the member
186 facing the spark port pressure chamber portion 108d defines an
annular seat 200 for the controller spring 190 and an annular
shoulder 202 for engaging the stop mechanism 192 and limiting
movement of the member 186 towards the housing end wall 180.
The diaphrabm member 188 allows the controller member 186 to freely
move towards and away from the housing end wall 180 under the
influence of the controller spring 190 and differential pressure
forces which effectively act on the member 186. The diaphragm
member 188 comprises an inner sealing flange 210 which is tightly
engaged about the periphery of the member 186, an outer sealing
flange 212 which is in sealing engagement with the housing member
104 and an intermediate flexible wall portion 214 continues with
the flanges 210, 212 for enabling the aforementioned movement of
the controller member 186.
In the preferred embodiment the outer sealing flange 212 is clamped
against the outer sealing flange 156 of the diaphragm 152 between
the housing members 104, 106 and, as illustrated in FIG. 2, a
portion of the venturi signal passage 164 extends through part of
the outer sealing flange 212.
The adjustable stop mechanism 192 comprises a generally annular
stop member 220 which is supported in the chamber portion 108d by
an adjustable screw 222 which extends through the housing end wall
180. The stop member 220 defines a central opening 224 which is
loosely received on the projecting end of the screw 222, an annular
bearing face 226 which extends radially away from the opening 224
and a spring seating flange 228 which extends peripherally about
and is offset from the plane of the bearing face 226 against which
the spring 190 seats..
The screw 222 is preferably disposed in a tapped hole 230 extending
through the housing end wall 180 with the threads of the hole 230
and screw 222 being engaged tightly to prevent leakage of
atmospheric air into the chamber portion 108d.
During operation of the engine when the throttle plate is away from
its closed, or idle, position but not at or substantially at the
wide open throttle position, the chamber portion 108d communicates
with a vacuum level at, or substantially at, the intake manifold
vacuum level via the spark port 63, the conduit 62, and the passage
182. Under these conditions the vacuum pressure level in the
chamber portion 108d is substantial and the member 186 is urged
upwardly against the stop member 220 in opposition to the
controller spring 190. This condition of the controller assembly
102 is illustrated in FIG. 2.
When the engine is operating at a cruising speed the controller
member 186 is in engagement with the abutment member 220 the
actuator spring 170 biases the actuator member 150 away from the
controller member 186 towards the atmospheric chamber portion 108b
to operate the regulator valve assembly 110 as described
previously.
As the throttle plate opens further to increase the engine speed or
accommodate a greater load at the cruising speed the venturi
vaacuum magnitude increases. When the venturi vacuum magnitude
reaches a predetermined level such as, for example, one inch of
mercury, the actuator spring 170 is compressed sufficiently that
the actuator member 150 engages the abutment 196 on the controller
member 186. When this occurs the actuator spring 170 is, in effect,
removed from the system and the actuator member 150 and controller
member 186 function is a unit. As noted previously, in this
condition of operation, the diaphragm valve assembly 110 is wide
open since the valve body 122 maintained in engagement with the
retainer ring flange 133 by the valve spring 125 and maximum
available EGR operating pressure is communicated to the EGR
valve.
If the throttle plate is opened still farther toward its wide open
position the vacuum level in the spark port pressure chamber 108d
is reduced towards atmospheric pressure sufficiently that the
controller spring 190 moves the controller member 186 and the
actuator member 150 towards the valve assembly 110. Since the
actuator member 150 and the controller member 186 function as a
unit, movement of the members 186, 150 towards the valve member is
determined by the pressure differential between the chamber
portions 108b and 108d and the force of the controller spring
190.
When the actuator member 150 re-engages the valve body 122, the
valve spring 125 begins to oppose further movement of the members
186 and 150 while the pressure in the chamber portion 108a creates
a pressure force on the diaphragm valve 110 tending to oppose the
valve spring 125. The valve spring 125 is compressed which tends to
reduce the pressure in the output chamber portion 108a and operate
the EGR valve 14 toward its closed position. It should be noted in
this connection that the controller spring 190 is substantially
stronger than the valve spring.
When the pressure in the spark port chamber portion 108d reaches a
desired level, e.g. approximately two-three inches of mercury, the
action of the controller spring 190 operates the diaphragm valve
assembly 110 to communicate atmospheric air from the chamber
portion 108b directly to the EGR valve 14. This vents the EGR valve
14 causing that valve to be positively closed. It should be noted
that venting of the EGR valve 14 occurs while the valving member
146 is seated on the port 115 and thus the reservoir 13a is not
vented to atmosphere even though the EGR valve 14 is so vented.
When the engine speed or load is reduced and the throttle plate is
moved away from its substantially wide open position, the member
186 moves toward the housing end wall 180 resulting in the
regulator 101 again supplying operating pressure to the EGR valve
14. It should be apparent that even if the movement of the throttle
plate away from its substantially wide open position is
accomplished quite gradually, since the reservoir 13a is not vented
when the EGR valve is closed at the wide open throttle condition,
sufficient power is available from the reservoir for operating the
EGR valve 14 from its closed position as the throttle plate is
moved towards its closed position.
When the engine is idling the throttle plate is substantially
closed and the spark port, since it is communicated with
atmospheric air pressure upstream from the closed throttle plate,
maintains the spark port chamber portion 108d at substantially
atmospheric pressure. Under this condition of operation of the unit
100 the small mass flow rate of air into the engine is such that
there is substantially no venturi vacuum signal and the chamber
portion 108c is accordingly effectively at atmospheric pressure.
When these conditions exist the controller spring 190 overcomes the
force of the actuator spring 170 causing the controller member 186
to engage the actuator member 150 and consequently urge the valve
body 122 towards the chamber portion 108a so that the EGR valve 14
is vented to atmosphere via the bore 142 in the valve member 122
and the chamber portion 108b. The diaphragm valve 110 is thus
prevented from communicating any operating pressure to the EGR
valve 14. The controller spring 190 overcomes the forces produced
by the actuator and valve springs 170, 125 and operates the
diaphragm valve 110 to its zero output pressure condition
notwithstanding the fact that the diaphragm valve 110 is preset to
produce an initial output pressure in the absence of an input
signal.
As soon as the throttle plate moves slightly away from its idle
position, the spark port is effectively exposed to the engine
intake manifold pressure, which is substantially in excess of 3
inches of mercury, causing the member 186 to abruptly compress the
controller spring 190 and move into engagement with the abutment
member 220. The actuator spring 170 becomes effective to force the
members 150, 186 apart and the position of the actuator member 150
is controlled by the actuator spring 170, the venturi vacuum signal
level present in the chamber portion 108c and the valve spring 125.
Accordingly the valve body 122 is shifted to produce at least the
preset initial output pressure level in the chamber portion 108a.
The output pressure is thereafter determined by the signal input
pressure as described previously.
Proper operation of the unit 100 requires selection of the springs
125, 170 and 190 so that the controller spring 190 provides a
greater force than both of the other two springs as it moves to its
fully extended condition. The controller spring 190 must also be
related to the controller assembly so that when the spark port
vacuum level exceeds a predetermined low level, e.g. 3 inches of
Mercury, the controller spring 190 is compressed sufficiently to
enable the member 186 to engage the abutment 220. The valve spring
125 is selected to provide force which is slightly in excess of the
force provided by the actuator spring 170 so that the initial
preset output vacuum level can be established in the chamber 108a
in the absence of venturi vacuum pressure.
To calibrate the operaation of the unit 100, the chamber portion
108d is evacuated to a level which seats the controller member 186
against the abutment member 220. In this condition the controller
spring 190 is ineffective to exert forces on the actuator member
150 or the valve body 122. The input pressure passage 118 is
communicated to a suitable source of vacuum pressure which is
capable of supplying vacuum to the valve 110 at a greater magnitude
than the desired preset initial output level from the chamber
portion 108a. A slight vacuum pressure, e.g. about 0.1 inches of
mercury it then supplied to the venturi signal chamber 108c and the
screw 222 is advanced or retracted from the housing member 104
until a desired valve operating pressure level is established in
the output chamber 108a.
This condition of the unit 100 duplicates the condition of the unit
100 when the engine is operated at a low speed cruise just above
idle speed and enables the desired opening of the EGR valve 14 to
be established under such conditions.
While two preferred embodiments of the present invention have been
illustrated and described herein in considerable detail the present
invention is not to be considered limited to the precise
constructions shown. Various adaptations, modifications and uses of
the invention will occur to those skilled in the art to which the
invention pertains. The intention is to cover all such adaptations,
modifications and uses which come within the scope or spirit of the
appended claims.
* * * * *