DE102004013309B4 - Intake system for an internal combustion engine - Google Patents

Abstract

Intake system for an internal combustion engine, in particular a motor vehicle, - with a fresh air manifold (2) in the use state on the input side via a supply line (4) supplied fresh air on the output side at least two cylinders of the internal combustion engine, - wherein the fresh air manifold (2) on the output side for each associated cylinder respectively contains a separate outflow channel (14), - wherein all outflow channels (14) emanating from a common distribution chamber (13) communicably connectable or connected to the supply line (4), all the outflow channels (14) being produced separately from the fresh air distributor (2) Function carrier (16) are formed, - wherein a flange (6) for attachment of the fresh air manifold (2) is provided on an engine block of the internal combustion engine, characterized in that the function carrier (16) in an output side receiving opening (17) of the fresh air manifold (2 ) used is, - that the flange (6) on the fresh air manifold (2) is integrally formed.

Description

The present invention relates to an intake system for an internal combustion engine, in particular of a motor vehicle, having the features of the preamble of claim 1.

Such an intake system regularly has a fresh air manifold, the input side in the state on the input side via a supply line supplied fresh air on the output side supplies at least two cylinders of the internal combustion engine. It is customary here for the output air side of the fresh air distributor to contain at least one separate outflow channel for each associated cylinder, all outflow channels originating from a common distributor space of the fresh air distributor communicably connected or connected to the supply line.

Since such an intake system, in particular if it is provided in an internal combustion engine of a motor vehicle, is a mass produced product, ways are always sought to produce such an intake system as inexpensively as possible. For this purpose, it is essential that any post-processing, for example for the manufacture of attachment points or bearings, are disproportionately cost-intensive. Furthermore, it should be considered that the intake system, at least individual areas thereof can be exposed to relatively high temperatures during use.

A generic suction system is z. B. from the JP H07-247 924 A known. It is characterized in that all outflow channels are formed in a separately produced by the fresh air distributor function, which is arranged in the known intake system in the installed state in the manner of an intermediate flange between the fresh air manifold and an engine block of the internal combustion engine.

Other suction systems are for example from the JP H05-99 088 A , of the US Pat. No. 6,446,617 B2 , of the EP 1 122 421 A2 , of the DE 100 45 636 A1 , of the EP 1 085 197 A2 , of the US Pat. No. 6,662,772 B1 , of the US 5 537 965 A , of the EP 1 186 779 A2 , of the EP 1455 081 A1 , of the JP H11-350 963 A and the US Pat. No. 1,818,283 A known.

The present invention is concerned with the problem of providing for an intake system of the type mentioned an improved embodiment, which is in particular comparatively inexpensive to produce.

This problem is solved according to the invention by the subject matters of the independent claims. Advantageous embodiments are the subject of the dependent claims.

The invention is based on the general idea of providing a function carrier which can be produced separately from the fresh air distributor and which contains the individual outflow channels and can be inserted into a complementary receiving opening formed on the fresh air distributor. In this way, fresh air manifold and function carrier can be made comparatively easy in each case, in particular so that no or only minor reworking are required at least on the fresh air manifold. The separately produced components can then be completed in an additional step simply by the fact that the function carrier is inserted into the fresh air manifold. The additionally required operation can be carried out readily with the same number of cycles as the production of fresh air manifold and the function carrier, which is advantageous for the concerns of mass production. According to the invention it is also provided that a flange, with which the fresh air manifold can be attached to an engine block of the internal combustion engine, is integrally formed on the fresh air manifold.

Other components of the intake system, which can be conveniently integrated into the function carrier or configured or attached to the function carrier in addition to the outflow channels are, for example, flaps, in particular swirl flaps, with the aid of which a swirl channel can be controlled. In this way, the entire boundary conditions, which must be observed with regard to the sealing and storage of such valves, be taken into account in the function carrier and thus have no influence on the production of the fresh air manifold.

According to a particularly advantageous embodiment of the fresh air manifold can now be used as an injection molded part, for. B. made of plastic or metal, in particular aluminum. The design of the fresh air manifold as an injection molded part includes a variety of measures that create the conditions to be able to produce the fresh air manifold by means of an injection molding process. For example, all cavities to be formed must be accessible by means of dies and slides or the like without undercuts, so that the same mold can be used over and over again. This offers a significant cost advantage over a lost-mold casting process, where after casting, a core must be melted out of the workpiece or otherwise removed. By integrating the outflow into the function carrier, the three-dimensional shape the fresh air manifold are considerably simplified, which is a crucial step to be able to produce the fresh air manifold as an injection molded part.

Other important features and advantages of the invention will become apparent from the dependent claims, from the drawings and from the associated figure description with reference to the drawings.

It is understood that the features mentioned above and those yet to be explained below can be used not only in the particular combination given, but also in other combinations or in isolation, without departing from the scope of the present invention.

A preferred embodiment of the invention is illustrated in the drawings and will be explained in more detail in the following description, wherein like reference numerals refer to identical or functionally identical or similar components.

Show, in each case schematically,

1 a top view of an intake system according to the invention,

2 a perspective view of the suction system,

3 a perspective view as in 2 , but partly as an exploded view,

4 a sectional view corresponding to the section lines IV in 1 .

5 a sectional view corresponding to the section lines V in 1 .

6 a simplified sectional view corresponding to the section lines VI in 5 ,

According to the 1 to 3 includes an intake system according to the invention 1 for fresh air supply of an internal combustion engine, in particular of a motor vehicle, a fresh air manifold 2 that is integral with an end section here 3 a supply line 4 is provided. In use, ie during operation of the internal combustion engine is the fresh air manifold 2 Fresh air on the input side via the supply line 4 fed. Inside the fresh air manifold 2 then the division of the fresh air supplied to several cylinders of the internal combustion engine, ie the fresh air manifold 2 leads these cylinders to the required fresh air. The fresh air manifold 2 is at one in the 2 and 3 the viewer facing flange side 5 designed for connection to an engine block of the internal combustion engine. Appropriately, this is the fresh air manifold 2 a corresponding flange 6 integrally formed. The suction system 1 can with the help of this flange 6 through screw holes 38 be bolted to the engine block.

The preferred embodiment of the intake system shown here 1 also has important components of an exhaust gas recirculation system 7 on, namely an exhaust gas recirculation valve 8th , On-off valve 9 and an exhaust gas cooler 10 , The said components of the exhaust gas recirculation device 7 form a separately preassembled module, which is completely on the fresh air manifold 2 can be mounted. The exhaust gas recirculation valve 8th controls, depending on its operation, the amount of recirculated into the fresh air exhaust gases. The switching valve 9 depending on its operation, the possibly recirculated exhaust gases either directly into an exhaust manifold described in more detail below 11 or through the exhaust gas cooler 10 indirectly in the exhaust manifold duct 11 , It is expedient in the particular embodiment shown here, the exhaust gas recirculation device 7 in a cooling circuit 12 of the exhaust gas cooler 10 the exhaust gas recirculation valve 8th integrated, whereby this can be actively cooled. Also this cooling circuit 12 forms part of the preassembled module, which is completely connected to the fresh air distributor 2 can be grown.

According to the 4 and 5 Contains the fresh air manifold 2 in its interior a distribution room 13 that with the fresh air manifold 2 connected supply line 4 is communicatively connected. Furthermore, the fresh air manifold contains 2 for each of the intake system 1 associated cylinder of the internal combustion engine at least one outflow channel 14 , wherein each outflow channel 14 from this distribution room 13 goes out, so that the fresh air supply to the individual cylinders through these outflow channels 14 he follows. In the specific embodiment shown here, two such outflow channels are provided for each cylinder, which also in the following 14a and 14b be designated. Here is the one outflow channel 14a permanently open while the other outflow channel 14b with the help of a flap 15 is controllable. For example, he serves with the flap 15 controllable outflow channel 14b for acting on a swirl channel or a tumble channel of the respective cylinder.

According to the invention, the intake system comprises 1 also a function holder 16 Separately from the fresh air manifold 2 is manufactured and at the or in the all outflow channels 14 are formed. At the flange side 5 is at the fresh air manifold 2 a receiving opening 17 trained, in which the function carrier 16 is used. The receiving opening 17 is on the output side, ie open to the engine block, on the fresh air manifold 2 designed. By the construction according to the invention is the production of the fresh air manifold 2 greatly simplified, since it now has a geometry that can be formed by means of an injection molding technique. For example, shows 3 that the receiving opening 17 virtually across all cylinders along the flange side 5 extends and so in particular forms no undercuts. Accordingly, the fresh air manifold 2 preferably produced as an injection molded part.

Basically, the fresh air manifold 2 be injection molded from plastic. However, preferred is an embodiment in which the fresh air manifold 2 is injection-molded from a metal, preferably from a light metal or from a light metal alloy, preferably aluminum or aluminum alloy. The function holder 16 may in turn be conveniently made of plastic, in particular injection molded. The separate design of fresh air manifold 2 and officials 16 also allows an adaptation of the materials used in each case to the prevailing special component requirements.

Due to the design of the fresh air manifold 2 As a metal or aluminum injection or die-cast part can be dispensed with in particular on metal sleeves, in a fresh air manifold 2 made of plastic in the screw holes 38 would have to be used to a permanent fixation of the fresh air manifold 2 to ensure the engine block.

As explained above, the intake system includes 1 expedient the exhaust gas recirculation device 7 , So that the possibly recirculated combustion exhaust gases can get into the supplied fresh air, is the fresh air manifold 2 on its outside with at least one discharge point 18 fitted.

In the preferred embodiment shown here, for each of the intake system 1 associated cylinder a separate discharge point 18 provided in the form of an opening, which is the distributor space 13 with the above exhaust manifold 11 communicating connects. By introducing the recirculated exhaust gases into the distributor room 13 Ensures that the exhaust gases are upstream of the discharge channels 14 in the fresh air manifold 2 reach. Furthermore, the positioning of the discharge points takes place 18 aligned with the respective associated cylinder or aligned to the respectively associated outflow channels 14 , In addition, the exhaust manifold extends 11 transverse to the flow direction of the fresh air in the discharge channels 14 over all cylinders, and as close as possible to the inlet of the respective outflow channels 14 , In this way, the shortest possible flow path for the recirculated exhaust gases within the fresh air manifold 2 achieved, so that the exhaust gas recirculation can be activated and deactivated very quickly. Furthermore, the exhaust gas recirculation takes place via the specifically positioned discharge points 18 cylinder-selective.

This also shows another advantage of the suction system according to the invention 1 , Because the fresh air manifold regardless of the outlet channels 14 containing function carrier 16 can be made, in particular heat-resistant materials such. As metals used. This is with regard to the exhaust gas recirculation of particular importance, since the recirculated exhaust gases here by a corresponding positioning of the discharge points 18 upstream of the discharge channels 14 in the distribution room 13 be initiated and downstream of the discharge points 18 be cooled by mixing with the fresh air. On the one hand, the introduced exhaust gases can therefore only the fresh air manifold 2 apply and thermally load, the fresh air manifold 2 by suitable choice of material this burden holds without further notice. On the other hand, the outflow channels 14 only acted upon by comparatively cool gases, so that for the function carrier preferably made of plastic 16 no problems arise here.

Like from the 4 and 5 is particularly clear, is the exhaust manifold 11 bisected in its longitudinal direction, so that the exhaust manifold duct 11 through a first channel section 11a and a second channel section 11b is formed, which are designed complementary to each other. It is important that the first channel section 11a from which the intake points 18 go off, directly on the fresh air manifold 2 is formed and in particular is made integral with this. In contrast, the second channel section forms 11b virtually a cover through which the possibly recirculated exhaust gases from the switching valve 9 and / or from the exhaust gas cooler 10 in the exhaust manifold duct 11 flow.

Of particular importance is also that substantially the entire intake manifold side exhaust gas recirculation device 7 at this second channel section 11b is attached and that this second channel section 11b for attachment to the fresh air manifold 2 is prepared. The attachment of the second channel section 11b and thus the suction pipe side components of the exhaust gas recirculation device 7 takes place here via one on the second channel section 11b trained flange 19 with the help of screws 20 which are in appropriate attachment points 21 intervene on the fresh air manifold 2 are formed. In particular, these attachment points are 21 integral, ie in the context of injection molding on the fresh air manifold 2 educated.

Appropriately are thus in the fresh air manifold 2 The following components integrated as possible so that no further post-processing is required: the attachment points 21 for flanging the exhaust gas recirculation device 7 , Further unspecified attachment points for mounting a drive member 39 for the drive shaft 23 , the flange 6 , the end section 3 the supply line 4 and the first channel section 11a including the discharge points 18 ,

Coming back to the 2 and 3 it can be seen that the officer 16 two separate outflow channels for each cylinder 14a and 14b contains, wherein the one outflow channel 14b each with the help of the flap 15 is controllable, in particular between a closed position and an open position. The flap 15 is designed here as a butterfly flap and in the controllable outflow channel 14b pivotally mounted. For this purpose, the respective flap 15 on a hollow bearing shaft 22 arranged rotationally fixed, in particular integrally formed on this. Every bearing shaft 22 is rotatable in the function carrier 16 stored. For simultaneous turning operation of all flaps 15 is a common drive shaft 23 provided coaxially with the axis of rotation of the flaps 15 or the bearing shafts 22 through all bearing shafts 22 extends through and is rotatably connected thereto. For example, has the drive shaft 23 this is a non-rotationally symmetrical profile, here z. B. a square profile, while the bearing shafts 22 have in their interior a complementary inner profile, whereby in the circumferential direction of the drive shaft 23 a positive connection with the bearing shafts 22 results.

Of particular importance now is that the drive shaft 23 in the installed state all bearing shafts 22 at the function carrier 16 guaranteed. Furthermore, the drive shaft 23 at one of its ends with the drive member 39 rotatably coupled, with an unrecognizable plug-in coupling part in the function carrier 16 and in the fresh air manifold 2 each rotatably penetrates in a circumferentially closed opening. The said openings are not visible in the representations shown here, but are in the range of an arrow 24 at the function carrier 16 or in the area of an arrow 25 at the fresh air manifold 2 educated. These openings 24 . 25 aligned with inserted function carrier 16 and are coaxial with the axes of rotation of the bearing shafts 22 aligned. In this way it forms into the openings 24 . 25 inserted and z. B. at the fresh air manifold 2 fastened by screws drive member 39 a positive lock for the function carrier 16 at the fresh air manifold 2 , Such a fuse can for the finished preassembled suction 1 serve as transport security.

Appropriately, the bearing shafts 22 in each case in at least two, here in each case three camps 26 at the function carrier 16 stored, including at the respective bearing shaft 22 corresponding hubs 27 are provided. In the case of the preferred variant shown here, each bearing is 26 from two complementary half-shells 26a and 26b educated. Each one is a half shell 26a at the function carrier 16 integrally formed, while the other half shell 26b on a storage cage 28 is formed integrally. Here is each camp cage 28 separately from the function carrier 16 produced and in a corresponding, at the function carrier 16 trained recording 29 used. For optimal positioning of the bearing cages 28 in the function carrier 16 can be formed corresponding, not designated here sliding seats, which is the introduction of the respective bearing cage 28 in the function carrier 16 as well as the fixation of the bearing cage 28 in the function carrier 16 simplify or support.

For assembly, the bearing shafts can now be used 22 in the functional carrier half shells 26a be inserted. Subsequently, the bearing cages can 28 in the associated recordings 29 be pushed, causing the bearings 26 be completed. According to the special embodiment shown here, the bearing cages have 28 at least two circumferentially closed openings 30 of which in 3 only one is visible at a time. In the inserted state of the bearing cage 28 are these openings 30 coaxial with the axis of rotation of the bearing shaft 22 positioned, causing the drive shaft 23 when inserted into the bearing shafts 22 also these openings 30 rotatably penetrates and thereby the bearing cages 28 positive fit on the function carrier 16 guaranteed. In this way forms the function carrier 16 together with the bearing shafts 22 and the camp cages 28 a pre-assembled unit, with the help of the drive shaft 23 held together.

The camp cages 28 are also shaped here so that they are the downstream ends of the discharge channels 14 define or complete.

For the gas-tight installation of the suction system 1 on the engine block of the internal combustion engine is also a separate from the function carrier 16 manufactured seal 31 provided on the flange side 5 is arranged and all outflow channels 14 circumferentially completely closed encloses. It can be the seal 31 according to the 2 and 3 between the discharge channels 14 adjacent cylinder webs 32 have, for each cylinder separately the associated outflow channels 14 to be completely closed in the circumferential direction. In this way, leakage from one cylinder to another within the seal can also occur 31 be avoided.

As in particular the 4 and 5 is removable, is on the flange side 5 a sealing groove 33 formed, which is complementary to the seal 31 and in particular to their webs 32 , runs. Accordingly, also encloses the sealing groove 33 the function holder 16 Completely complete. According to the particular embodiment shown here, the sealing groove 33 divided in her profile and accordingly by a first paragraph 33a and an opposite second paragraph 33b educated. The two paragraphs 33a . 33b are complementary to each other and complement each other to open the engine block sealing groove 33 , The first paragraph 33a is at the function carrier 16 formed circumferentially outside, while the second paragraph 33b at the fresh air manifold 2 in the area of the receiving opening 17 is formed circumferentially inside. The two paragraphs 33a . 33b abut against each other at the bottom of the groove, preferably approximately centrally with respect to the sealing groove 33 , In this way, the seals in the sealing groove 33 used seal 31 at the bottom of the groove the shock and thus the function carrier 16 opposite the fresh air manifold 2 , When assembled, the gasket can 31 also sealing on the outside of the second paragraph 33b , so at the fresh air manifold 2 and / or inside the first paragraph 33a So, at the function carrier 16 issue. Otherwise, the seal lies 31 on the side facing away from the groove base on the engine block.

Corresponding 6 is between the supply line 4 or its end section 3 and the fresh air manifold 2 a transition 34 formed, which is characterized here by a curly bracket. It is clear that the supply line 4 with its end section 3 to the fresh air manifold 2 in the area of this transition 34 can be grown. However, preferred is the embodiment shown here, in which the supply line 4 or its end section 3 integral on fresh air manifold 2 is formed.

According to the invention is now in a flow path of an interior 35 the supply line 4 or their end section 3 to the distribution room 13 leads, at the transition 34 a spoiler-like edge 36 educated. During operation of the suction system 1 leads this edge 36 in addition to a fresh air flow indicated by arrows 37 when entering the distributor room 13 can widen and spread better, reducing the outflow channels 14 of the fresh air manifold 2 be streamed evenly or be supplied with fresh air. In particular, those outflow channels 14 , for those in the distribution room 13 quasi a return flow must be achieved (in 6 right), this results in significantly improved flow conditions.

It is clear that the edge 36 at the suction system 1 It can be completely independent of whether the intake system 1 with the function carrier produced as a separate component 16 equipped or not.

According to the in the 1 to 6 the embodiment shown is the feed line 4 or its end section 3 at the fresh air manifold 2 appropriately arranged so that the interior 35 to the distribution room 13 leading flow path at the transition 34 is deflected by about 90 °. Following the transition 34 takes place in the distribution room 13 in addition, the desired expansion of the flow 37 and thus their distribution to the individual outflow channels 14 ,

Claims (12)

Intake system for an internal combustion engine, in particular a motor vehicle, - with a fresh air distributor ( 2 ), which in use on the input side via a supply line ( 4 supplied fresh air on the output side, at least two cylinders of the internal combustion engine, - wherein the fresh air manifold ( 2 ) on the output side for each associated cylinder each have a separate outflow channel ( 14 ), all the outflow channels ( 14 ) from one to the supply line ( 4 ) communicably connectable or connected common distribution space ( 13 ), with all outflow channels ( 14 ) in a separate from the fresh air manifold ( 2 ) ( 16 ) are formed, - wherein a flange ( 6 ) for fastening the fresh air distributor ( 2 ) is provided on an engine block of the internal combustion engine, characterized in that - the function carrier ( 16 ) in an output-side receiving opening ( 17 ) of the fresh air distributor ( 2 ), that the flange ( 6 ) at the fresh air distributor ( 2 ) is integrally formed. Intake system according to claim 1, characterized in that the fresh air distributor ( 2 ) is an injection molded part. Intake system according to claim 1 or 2, characterized in that the fresh air distributor ( 2 ) outside at least one or for each associated cylinder at least one with the distribution space ( 13 ) communicatively connected discharge point ( 18 ), by the recirculated exhaust gases of the internal combustion engine in the distribution chamber ( 13 ) can be introduced. Vacuum system according to claim 3, characterized in that - all the discharge points ( 18 ) in use with an exhaust manifold ( 11 ) an exhaust gas recirculation device ( 7 ) are communicatively connected, - that the exhaust gas distribution channel ( 11 ) by one at the fresh air distributor ( 2 ) formed first channel section ( 11a ) from which the discharge points ( 18 ) and a complementary second channel section ( 11b ) is formed, through which the recirculated exhaust gases in the exhaust gas distribution channel ( 11 ). Intake system according to one of claims 1 to 4, characterized in that - the fresh air distributor ( 2 ) is made of metal and / or - that the function carrier ( 16 ) with the outflow channels ( 14 ) is made of plastic. Intake system according to one of claims 1 to 5, characterized in that at the fresh air manifold ( 2 ) Attachment points ( 21 ) for connecting attachments to the fresh air manifold ( 2 ) and / or at least one end portion ( 3 ) of the supply line ( 4 ) is integrally formed. Intake system according to one of claims 1 to 6, characterized in that - the function carrier ( 16 ) for each associated cylinder in at least one outflow channel ( 14b ) a pivotally mounted flap ( 15 ), with which the associated outflow channel ( 14b ) is controllable, - that each flap ( 15 ) rotatably on a hollow rotatably mounted bearing shaft ( 22 ), that all flaps ( 15 ) via a common drive shaft ( 23 ) which can be actuated simultaneously by all bearing shafts ( 22 ) is inserted coaxially and rotatably connected to these, - that the drive shaft ( 23 ) at one end with a drive member ( 39 ) is rotatably connected, which for this purpose both the function carrier ( 16 ) as well as the fresh air distributor ( 2 ) in mutually aligned, circumferentially closed openings ( 24 . 25 ) rotatably penetrates and thereby the function carrier ( 16 ) positively on the fresh air manifold ( 2 ) secures. Intake system according to claim 7, characterized in that - each bearing shaft ( 22 ) in at least two warehouses ( 26 ) is rotatably mounted, - that each bearing ( 26 ) of two complementary half-shells ( 26a . 26b ), of which the one half shell ( 26a ) at the function carrier ( 16 ) and the other half shell ( 26b ) on a bearing cage ( 28 ) is integrally formed, - that each bearing cage ( 28 ) separately from the function carrier ( 16 ) and in one at the function carrier ( 16 ) trained recording ( 29 ) is used. Suction unit according to claim 8, characterized in that each bearing cage ( 28 ) at least two coaxial with the bearing shaft ( 22 ) positioned, circumferentially closed openings ( 30 ) provided by the drive shaft ( 23 ) are rotatably penetrated, whereby the drive shaft ( 23 ) the bearing cages ( 28 ) form-fitting on the function carrier ( 16 ) secures. Intake system according to one of claims 1 to 9, characterized in that a separate from the function carrier ( 16 ) produced seal ( 31 ) on an intended for connection to an engine block of the internal combustion engine flange ( 5 ) of the fresh air distributor ( 2 ) in a sealing groove ( 33 ), which is the function holder ( 16 ) completely encloses the circumference and the one by the function carrier ( 16 ) outer circumferential first paragraph ( 33a ) and one on the first paragraph ( 33a ) complementary to the fresh air distributor ( 2 ) inner circumferential second paragraph ( 33b ) is formed. Intake system according to one of claims 1 to 10, characterized in that in the flow path at the transition ( 34 ) between the supply line ( 4 ) and the fresh air distributor ( 2 ) a spoiler-like edge ( 36 ) is trained. Intake system according to claim 11, characterized in that the supply line ( 4 ) so at the fresh air manifold ( 2 ) is arranged such that the flow path at the transition ( 34 ) is deflected by about 90 °.

Images