CAM TORQUE ACTUATED PHASER USING BAND CHECK VALVES BUILT INTO A CAMSHAFT OR CONCENTRIC CAMSHAFTS

Abstract

A camshaft assembly in which a bearing (49) includes a first passage (18) for introducing makeup oil to the phaser and a second passage (52) for controlling spool (20) position and lock pin (42) position. In an alternative embodiment the bearing (49) is replaced by pieces on the outer shaft and bearings. The pieces on the outer shaft (149, 150) house the advance and retard annuluses and ports in the inner and outer shafts. A first bearing (147) provides makeup fluid to the phaser and a second bearing (151) provides fluid for controlling the position of the spool and the lock pin position.

Description

REFERENCE TO RELATED APPLICATIONS

This application claims one or more inventions which were disclosed in Provisional Application No. 61/098,289, filed Sep. 19, 2008, entitled “CAM TORQUE ACTUATED PHASER USING BAND CHECK VALVES BUILT INTO A CAMSHAFT OR CONCENTRIC CAMSHAFTS” and in Provisional Application No. 61/098,274, filed Sep. 19, 2008, entitled, “PHASER BUILT INTO A CAMSHAFT OR CONCENTRIC CAMSHAFTS”. The benefit under 35 USC §119(e) of the United States provisional application is hereby claimed, and the aforementioned applications are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention pertains to the field of cam timing. More particularly, the invention pertains to a can torque actuated phaser using band check valves built into a camshaft or concentric camshafts.

2. Description of Related Art

Cam in cam systems are well know in the prior art. In prior art cam in cam systems, the camshaft has two shafts, one positioned inside of the other.

SUMMARY OF THE INVENTION

A camshaft assembly for an internal combustion engine comprising: a hollow outer shaft with annuluses along a length of the shaft; an inner shaft having ports along a length of the inner shaft and forming a bore at one end of the inner shaft; the inner shaft received within the hollow outer shaft, such that the ports along the length of the inner shaft are aligned with the annuluses along the length of the outer shaft and cam lobes. The assembly also includes a phaser comprising: a housing an outer circumference for accepting a drive force; a rotor coaxially located within the housing, the housing and the rotor defining at least one vane separating a chamber in the housing into advance and retard chambers, the vane being capable of rotation to shift the relative angular position of the housing and the rotor; and a control valve received within the bore of the inner shaft comprising a spool with a plurality of metered slots; at least one bearing adjacent to the second cam lobe and the housing of the phaser on the outer shaft having a first passage connected to a pressurized source for providing makeup oil to the phaser and a second passage in fluid communication with a valve for controlling the position of a spool and state of the lock pin.

The camshaft assembly may be used for a multiple cylinder engine or a single cylinder engine. In single cylinder engines, at least one cam lobe is directly attached or hard pressed to the outer shaft and at least one other cam lobe is directly attached or hard pressed to the inner shaft.

In multiple cylinder engines, the outer shaft is hollow with multiple slots (not shown) that run perpendicular to the axis of rotation and has a sprocket attached to the outside of the outer shaft. Inside the hollow outer shaft is a hollow inner shaft with multiple holes (not shown) that run perpendicular to the length of the shaft. A first set of cam lobes are rigidly attached to the outer shaft and a second set of cam lobes are free to rotate and placed on the outer shaft with a clearance fit. The second set of cam lobes are positioned over slots (not shown) on the outer shaft and are controlled by the inner shaft through a mechanical connection (not shown).

In an alternative embodiment the bearing is replaced by thrust caps and bearings on the outer shaft. The thrust caps house the advance and retard annuluses and ports in the inner and outer shafts. A first bearing provides makeup fluid to the phaser and a second bearing provides fluid for controlling the position of the spool and the lock pin position. Alternatively, the thrust cap may be a bearing, part of the back plate of the phaser, or any part on the outer shaft.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 shows a first embodiment of the present invention.

FIG. 2 shows an exploded view of the first embodiment of the present invention.

FIG. 3 shows a sectional view of the phaser of the first embodiment of the present invention.

FIG. 4 shows another sectional view of the phaser of the first embodiment of the present invention with the control valve moving towards a fully forward position.

FIG. 5 shows a cross-section of FIG. 4 along line S-S with the control valve moving towards a fully forward position.

FIG. 6 shows a cross-section of FIG. 4 alone line U-U with the control valve moving towards a fully forward position.

FIG. 7 shows a sectional view of the first embodiment of the present invention with the control valve moving towards a fully back position.

FIG. 8 shows a cross-section of FIG. 7 along line S-S with the control valve moving towards a fully back position.

FIG. 9 shows a cross-section of FIG. 7 along line U-U with the control valve moving towards a fully back position.

FIG. 10 shows a sectional view of the first embodiment of the present invention with the control valve in the mid position.

FIG. 11 shows a cross-section of FIG. 10 along line S-S with the control valve in mid position.

FIG. 12 shows a cross-section of FIG. 10 along line U-U with the control valve in mid position.

FIG. 13 shows an exploded view of the second embodiment of the present invention.

FIG. 14 shows another sectional view of the phaser of the second embodiment of the present invention with the control valve moving towards a fully forward position.

FIG. 15 shows a cross-section of FIG. 14 along line W-W with the control valve moving towards a fully forward position.

FIG. 16 shows a cross-section of FIG. 14 along line V-V with the control valve moving towards a fully forward position.

FIG. 17 shows a sectional view of the second embodiment of the present invention with the control valve moving towards a fully back position.

FIG. 18 shows a cross-section of FIG. 17 along line W-W with the control valve moving towards a fully back position.

FIG. 19 shows a cross-section of FIG. 17 along line V-V with the control valve moving towards a fully back position.

FIG. 20 shows a sectional view of the second embodiment of the present invention with the control valve in the mid position.

FIG. 21 shows a cross-section of FIG. 20 along line W-W with the control valve in mid position,

FIG. 22 shows a cross-section of FIG. 20 along line V-V with the control valve in mid position.

FIG. 23 shows an exploded view of an alternate embodiment of the present invention

DETAILED DESCRIPTION OF THE INVENTION

FIGS. 1-12 show a camshaft assembly 40 attached to a phaser 70 of a first embodiment of the present invention. The camshaft assembly 40 has an inner shaft 4 and an outer shaft 2.

The camshaft assembly 40 may be for a multiple cylinder engine or a single cylinder engine.

For a multiple cylinder engine, the outer shaft 2 is hollow with multiple slots (not shown) that run perpendicular to the axis of rotation and has a sprocket 14 attached to the outside of the outer shaft 2. Inside the hollow outer shaft 2 is a hollow inner shaft 4 with multiple holes (not shown) that run perpendicular to the length of the shaft. A first set of cam lobes 6 are rigidly attached to the outer shaft 2 and a second set of cam lobes 8 are free to rotate and placed on the outer shaft 2 with a clearance fit. The second set of cam lobes 8 are positioned over slots (not shown) on the outer shaft 2 and are controlled by the inner shaft 4 through a mechanical connection (not shown).

For single cylinder engines, the outer shaft 2 is hollow and has a sprocket 14 attached to the outside of the outer shaft 2. Inside the hollow outer shaft 2 is a hollow inner shaft 4. At least one cam lobe 6 is directly attached or hard pressed to the outer shaft and at least one other cam lobe 8 is directly attached or hard pressed to the inner shaft 4. At one end of the camshaft assembly, the rotor 10 of the phaser 70 is rigidly attached to the inner shaft 4.

Internal combustion engines have employed various mechanisms to vary the angle between the camshaft and the crankshaft for improved engine performance or reduced emissions. The majority of these variable camshaft timing (VCT) mechanisms use one or more “vane phasers” on the engine camshaft (or camshafts, in a multiple-camshaft engine). In most cases, the phasers have a rotor 10 with one or more vanes 10a, mounted to the end of the camshaft assembly 40, surrounded by or coaxially located within the housing 12. The housing 12 and the rotor 10 form chambers in which the vanes 10a fit, dividing the chambers into advance chambers 3 and retard chambers 5. The vane 10a is capable of rotation to shift the relative angular position of the housing 12 and the rotor 10. It is possible to have the vanes 10a mounted to the housing 12, and the chambers in the rotor 10, as well. A portion of the housing's outer circumference forms the sprocket 14, pulley or gear accepting drive force through a chain, belt, or gears, usually from the crankshaft, or possible from another camshaft in a multiple-cam engine. Front end plate 43 is bolted to the front side of the housing 12. The back plate 41 is formed as part of the housing 12 and sprocket. Alternatively, as shown in FIG. 23, a separate back plate 41 may be bolted to the backside of the housing 12. A vent 43a is present in the front end plate 43 and is aligned with the control valve 21 of the phaser 70.

The phaser 70 adjusts the phase of the outer and inner shafts 2, 4 relative to each other. The end of the inner shaft 4 of the camshaft assembly 40 has a bore 4c that forms a sleeve for receiving the spool 20 of the control valve 21 of the phaser 70. The spool 20 has a first end with a recess 20a that receives a spring 23 and second end 20e that that engages an alignment plug 50 present within the inner shaft 4, preventing the spool 20, from rotating relative to the inner shaft 4. The spring 23 biases the spool 20 in a first direction away from the front plate 43. The spool 20 also has metering slots 20b, 20c, 20d that aid in directing fluid to the advance and retard chambers 3, 5 and to a lock pin 42.

Between the first cam lobe 6 and the back end plate 41 is a first wide bearing 49 and adjacent to the second cam lobe 8 is second bearing 51. Within the first wide bearing 49 are two main passages 18, 52 that lead to aligned ports and annuluses in the outer and inner shafts 2, 4. The annuluses 28, 30, 32 in the outer shaft 2 are aligned with the ports 29, 31, 27 on the inner shaft 4 and the metered slots 20b, 20c, 20d of the spool 20 depending on the position of the spool 20 within the inner shaft 4. The first passage 18 in the first wide bearing 49 supplies fluid to the phaser 70 and feeds the bearing 49. The first passage 18 is in fluid communication with a groove 19 in the first wide bearing 49 that is aligned with three annuluses 28, 30, 32 in the outer shaft 2, an advance annuluses 28 in the outer shaft 2 leading to an advance port 29 in the inner shaft 4, a supply or common annulus 30 in the outer shaft 2 leading to a central port 31 in the inner shaft 4, and a retard annulus 32 in the outer shaft 2 leading to a retard port 27 in the inner shaft 4. The advance annulus 28, the retard annulus 30, and the first passage 18 each have a check valve present 34, 36, 22 respectively. The check valves 34, 36, 22 are preferably band check valves or disc check valves, although other types of check valves may also be used.

The second passage 52 in the first wide bearing 49 supplies fluid that controls the lock pin 42 and biases the position of the spool 20 of the control valve 21 in a second direction, towards the front plate 43, via a valve 62. The valve 62 may be an on/off valve with a constant source of pressurized fluid or an infinitely variable valve.

The lock pin 42 is present within a bore 10b in the rotor 10 of the phaser. The lock pin 42 includes a lock pin body 46 and a spring 43. The spring 43 biases the lock pin body 46 towards a locked position in which the lock pin body 46 engages a recess 53 in the housing 12 and the housing 12 is locked relative to the rotor 10. In an unlocked position, fluid biases the lock pin body 46 away from the recess 53 in the housing 12 and against the spring 43. It should be noted that while the lock pin 42 is shown in the rotor 10 and engages the housing 12 to lock the housing 12 relative to the rotor 10, the lock pin 42 may be present in the housing 12 and engage the rotor 10.

FIGS. 4-6 show the control valve moving towards a fully forward position. Fluid from a pressurized source of fluid moves through valve 62 to the second passage 52 in the first wide bearing 49 to a groove 60 formed within the outer shaft 2 between the outer shaft 2 and the inner shaft 4. From the groove 60, fluid flows through a port 4a in the inner shaft 4 into metered slot 20d that extends a substantial length of the spool 20, however not the entire length of the spool, with one end of the metered slot 20d open to chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 and the other end of the metered slot 20d is aligned with passage 47 in the rotor 10 leading to the lock pin 42. The fluid pressure of the fluid supplied to chamber 64 is greater than the spring force of spring 23 and the fluid in chamber 64 biases the second end 20e of the spool 20 towards the front plate 43 of the phaser 70, aligning the metered slot 20d with lock pin passage 47 in the rotor 10 and allowing fluid from the valve 62 to bias the lock pin 42 to an unlocked position.

With the spool 20 moving towards the fully forward position, the metering slot 20c is aligned with the advance annulus 28 and port 29 and the common annulus 30 and port 31, and advance chamber annulus portion 37a connecting the metered slot 20c to the advance passage 33 leading to the advance chamber 3. With the spool 20 moving towards the fully forward position, metering slot 20b is aligned with the retard annulus 32 and port 27, and retard chamber annulus portion 37b connecting the metered slot 20b to the retard passage 35 leading to the retard chamber 5.

With the spool 20 moving towards the fully forward position, fluid from the advance chamber 3 flows through advance passage 33 in the rotor 10 through the advance chamber annulus portion 37a in the inner shaft 4 to the metered slot 20c on the spool 20 to the advance port 29 and the common line port 31. Fluid is prevented from entering the advance annulus 28 by check valve 34. From the common line port 31, fluid enters the common annulus 30 and groove 19 leading to the retard annulus 32 and port 27. From the retard port 27, fluid enters metered slot 20b and the retard chamber annulus portion 37b to the retard passage 35 leading to the retard chamber 5, moving the vane 10a in the direction shown by the arrow in FIG. 4. Fluid is prevented from exiting the retard chamber 5 by the retard check valve 36. Fluid is prevented from flowing back to the pressurized source (not shown) through the first passage 18 by check valve 22. Fluid is supplied to phaser 70 by inlet line 18 from a pressurized source (not shown) to make up for leakage only.

FIGS. 7-9 show the control valve 21 moving towards a fully back position. Valve 62 is moved to a vent position, and fluid present in the bore 10b housing the lock pin 42, the metered slot 20d and the chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 vent to sump. With the fluid from the bore 10b housing the lock pin 42 draining to sump, the lock pin spring 43 biases the lock pin body 46 towards engagement with the recess 53 in the housing 12, and when the lock pin 42 is alignment with the recess 53 in the housing, the lock pin is moved to a locked position in which the housing 12 is locked relative to the rotor 10. With the fluid in the chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 venting to sump, the force of the spring 23 is greater than the force of the fluid in chamber 64 on the second end of the spool, and the spool moves away from, the front plate 43.

With the spool 20 moving towards the fully back position, the metering slot 20c is aligned with the advance annulus 28 and port 29 and advance chamber annulus portion 37b connecting the metered slot 20c to the advance passage 33 leading to the advance chamber 3. Additionally, the metered slot 20b is aligned with the retard annulus 32 and port 27 and the common annulus 30 and port 31 and retard chamber annulus portion 37b connecting the metered slot 20b to the retard passage 35 leading to the retard chamber 5.

With the spool 20 moving towards the fully back position, fluid from the retard chamber 5 flows through retard passage 35 in the rotor 10 through retard chamber annulus portion 37b in the inner shaft 4 to the metered slot 20b on the spool 20 to the retard port 27 and the common line port 31. Fluid is prevented from entering the retard annulus 32 by check valve 36. From the common line port 31, fluid enters the common annulus 30 and groove 19 leading to the advance annulus 28 and a port 29. From the advance port 29, fluid enters metered slot 20c and port 29 to the advance passage 33 leading to the advance chamber 3, moving the vane 10a in the direction shown by the arrow in FIG. 7. Fluid is prevented from exiting the advance chamber 3 by the advance check valve 34. Fluid is prevented from flowing back to the pressurized source (not shown) through the first passage 18 by check valve 22. Fluid is supplied to phaser by inlet line 18 from a pressurized source (not shown) to make up for leakage only.

FIGS. 10-12 shows a mid position. In the mid position, the force on the first end of the spool 20 by the spring 23 equals the force of the fluid in chamber 64 on the second end 20e of the spool 20, such that the metered slot 20c is open to the advance annulus 28 and port 29 and advance chamber annulus portion 37a leading to the advance passage 33 and the advance chamber 3 and metered slot 20b is open to the retard annulus 32 and port 27 and retard chamber annulus portion 37b leading to the retard passage 35 and the retard chamber 5. Makeup oil is supplied to the phaser 70 from a pressurized source (not shown) to make up for leakage and enters line 18 in the first wide bearing 49. From the inlet line 18, fluid enters groove 19 within the first wide bearing 49 and enters the advance annulus 28, through the advance check valve 34 and the advance port 29 to metered slot 20c of the spool 20 which leads to the advance chamber annulus portion 37a and advance passage 33 leading to the advance chamber 3. The fluid from groove 19 also enters the retard annulus 32 through the retard check valve 36 and the retard port 27 to the metered slot 20b of the spool 20 which leads to the retard chamber annulus portion 37b and the retard passage 35 leading to the retard chamber 5. Fluid is prevented from exiting the common line annulus 30 or port 31 by the spool 20.

Fluid is also directed through the second passage 52 in the first wide bearing 49 to a groove 60 formed within the outer shaft 2 between the outer shaft 2 and the inner shaft 4 by valve 62. From the groove 60, fluid flows through an annulus 4a in the inner shaft 4 into metered slot 20d that extends a substantial length of the spool 20, however not the entire length of the spool, with one end of the metered slot 20d open to chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 and the other end aligned with passage 47 in the rotor 10 leading to the lock pin 42. With the spool in the mid position, fluid flows from the valve 62, through groove 60 and metered slot 20d to passage 47 in the rotor 10, biasing the lock pin body 46 against the lock pin spring 44 moving the lock pin 42 to an unlocked position.

FIGS. 13-22 show a camshaft assembly 140 attached to a phaser of a second embodiment of the present invention. The camshaft assembly 140 has an inner shaft 4 and an outer shaft 2. The camshaft assembly of the second embodiment may be for a multiple cylinder engine or a single cylinder engine.

For a multiple cylinder engine, the outer shaft 2 is hollow with multiple slots (not shown) that run perpendicular to the axis of rotation and has a sprocket 14 attached to the outside of the outer shaft 2. Inside the hollow outer shaft 2 is a hollow inner shaft 4 with multiple holes (not shown) that run perpendicular to the length of the shaft. A first set of cam lobes 6 are rigidly attached to the outer shaft 2 and a second set of cam lobes 8 are free to rotate and placed on the outer shaft 2 with a clearance fit. The second set of cam lobes are positioned over slots (not shown) on the outer shaft 2 and are controlled by the inner shaft 4 through a mechanical connection (not shown).

For single cylinder engines, the outer shaft 2 is hollow and has a sprocket 14 attached to the outside of the outer shaft 2. Inside the hollow outer shaft 2 is a hollow inner shaft 4. At least one cam lobe 6 is directly attached or hard pressed to the outer shaft and at least one other cam lobe 8 is directly attached or hard pressed to the inner shaft 4. At one end of the camshaft assembly, the rotor 10 of the phaser 70 is rigidly attached to the inner shaft 4.

Internal combustion engines have employed various mechanisms to vary the angle between the camshaft and the crankshaft for improved engine performance or reduced emissions. The majority of these variable camshaft timing (VCT) mechanisms use one or more “vane phasers” on the engine camshaft (or camshafts, in a multiple-camshaft engine). In most cases, the phasers have a rotor 10 with one or more vanes 10a, mounted to the end of the camshaft assembly, surrounded by or coaxially located within the housing 8. The housing and the rotor form chambers in which the vanes 10a fit, dividing the chambers into advance chambers 3 and retard chambers 5. The vane 10a is capable of rotation to shift the relative angular position of the housing 12 and the rotor 10. It is possible to have the vanes 10a mounted to the housing 12, and the chambers in the rotor 10, as well. A portion of the housing's outer circumference forms the sprocket 14, pulley or gear accepting drive force through a chain, belt, or gears, usually from the crankshaft, or possible from another camshaft in a multiple-cam engine. Front end plate 43 is bolted to the front side of the housing 12. The back plate 41 is formed as part of the housing 12 and sprocket. Alternatively, as shown in FIG. 23, a separate back plate 41 may be bolted to the backside of the housing 12. A vent 43a is present in the front end plate 43 and is aligned with the control valve 20 of the phaser 70.

The phaser 70 adjusts the phase of the shafts 2, 4 relative to each other. The end of the inner shaft 4 of the camshaft assembly 140 has a bore 4c that forms a sleeve for receiving the spool 20 of the control valve 21 of the phaser. The spool 20 has a first end with a recess 20a that receives a spring 23 and a second end 20e that engages an alignment plug 50 present within the inner shaft 4, preventing the spool 20 from rotation. The spring 23 biases the spool 20 in a first direction away from the front plate 43. The spool 20 also has metering slots 20b, 20c, 20d that aid in direction fluid to the advance and retard chambers 3, 5 and to a lock pin 42. It should be noted that in this embodiment the spool and the metered slots are longer than the spool in the first embodiment so that the ports and annuluses in the thrust caps 149, 150 are aligned with appropriate metered slots in the spool.

Between the first cam lobe 6 and the back end plate 41 are a first thrust cap 149 immediately adjacent to the back end plate 41, a first bearing adjacent to the first thrust cap 149 and then a second thrust cap 150 adjacent to the first bearing 147 and the first cam lobe 6. A second bearing 151 is present between the first cam lobe 6 and the second cam lobe 8.

Within in the first bearing 147 is a passage 118 that supplies fluid to the phaser 70 and feeds the bearing 147. The first passage 118 is in fluid communication with a common line annulus 130 and a common line port 131 in the outer shaft 2 that leads to an annulus 119 in the outer shaft 2. The annulus 119 in the outer shaft 2 extends to a second advance port 128b within the outer shaft 2 in fluid communication with a chamber 150a within the second thrust cap 150 and to a second retard port 132b within the outer shaft 2 in fluid communication with a chamber 149a within the first thrust cap 149. Also within the chamber 150a of the second thrust cap 150 is a first advance port 128a and a first advance annulus 129a of the outer shaft 2 aligned with a third advance port 129 on the inner shaft 4 which is in fluid communication with metered slot 20c of the spool 20. Within the chamber 149a of the first thrust cap 149 is a first retard port 132a and a first retard annulus 127a of the outer shaft 2 aligned with a third retard port 127 on the inner shaft 4 which is in fluid communication with metered slot 20b of the spool 20. The first advance annulus 129a and the first retard annulus 127a each have a check valve 134, 136 present. An inlet check valve 122 within fluid passage 118 may also be present. The check valves 134, 136, 122 are preferably band check valves or disc check valves, although other types of check valves may also be used.

Within the second bearing 151 is a second passage 152 that supplies fluid that controls the lock pin 42 and biases the position of the spool 20 of the control valve 21 in a second direction, towards the front plate 43, via a valve 62. The valve 62 may be an on/off valve with a constant source of pressurized fluid or an infinitely variable valve.

The lock pin 42 is present within a bore 10b in the rotor 10 of the phaser. The lock pin includes a lock pin body 46 and a spring 44. The spring 44 biases the lock pin body 46 towards a locked position in which the lock pin body 46 engages a recess 53 in the housing 12 and the housing 12 is locked relative to the rotor 10. In an unlocked position, fluid biases the lock pin body 46 away from the recess 53 in the housing 12 and against the spring 44. It should be noted that while the lock pin 42 is shown in the rotor 10 and engages the housing 12 to lock the housing 12 relative to the rotor 10, the lock pin 42 may be present in the housing 12 and engage the rotor 10.

FIGS. 14-16 show the control valve moving towards a fully forward position. Fluid from a pressurized source of fluid moves through valve 62 to the second passage 52 in the second bearing 151 to an annulus 160 formed within the outer shaft 2 between the outer shaft 2 and the inner shaft 4. From the annulus 160, fluid flows through a port 4a in the inner shaft 4 into metered slot 20d that extends a substantial length of the spool 20, however not the entire length of the spool, with one end of the metered slot 20d open to chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 and the other end aligned with passage 4′7 in the rotor leading to the lock pin 42. The fluid pressure of the fluid supplied to chamber 64 is greater than the spring force of spring 23 and the fluid in chamber 64 biases the second end 20e of the spool 20 towards the front plate 43 of the phaser 70, aligning the metered slot 20d with lock pin passage 47 in the rotor 10 and allowing fluid from the valve 62 to bias the lock pin 42 to an unlocked position.

With the spool 20 moving towards the fully forward position, the metering slot 20c is aligned with the third advance port 129, the first advance annulus 129a, and the first advance port 128a, and the advance chamber annulus 37a connecting the metered slot 20c to the advance passage 33 leading to the advance chamber 3, and the common port 131 and common annulus 130. With the spool 20 moving towards the fully forward position, metering slot 20b is aligned with the third retard port 127, the first retard annulus 127a, and the first retard port 132a, and the retard chamber annulus 37b, connecting the metered slot 20b to the retard passage 35 leading to the retard chamber 5.

With the spool 20 moving towards the fully forward position, fluid from the advance chamber 3 flows through advance passage 33 in the rotor 10 through advance chamber annulus portion 37a in the inner shaft 4 to the metered slot 20c on the spool 20 to the third advance port 129 and the common port 131. Fluid is prevented from entering the first advance port 128a by check valve 134. From the common line port 131, fluid enters the common annulus 130 and annulus 119. From the annulus 119, fluid flows through the second retard port 132b, into chamber 149a of the first thrust cap 149 and through the first retard port 132a and first retard annulus 127a and check valve 136, through the third retard port 127 and into metered slot 20b. From the metered slot 20b, fluid flows into the retard chamber annulus 37b in the inner shaft 4 to the retard passage 35 in the rotor 10 to the retard chamber 5, moving the vane 10a in the direction show by the arrow in FIG. 14. Fluid is prevented from exiting the retard chamber 5 by the retard check valve 136. Fluid is prevented from flowing back to the pressurized source through inlet passage 118 by check valve 22. Fluid from annulus 119 that flows through the third advance port 129, through the first advance annulus 129a and check valve 134 and the first advance port 128a and into the chamber 150a of the second thrust cap 150 will flow into the metered slot 20c leading back to the annulus 119 and to the retard chamber 5. Fluid is supplied to the phaser by inlet line 118 from a pressurized source (not shown) to make up for leakage only.

FIGS. 17-19 show the control valve 62 moving towards a fully back position. Valve 62 is moved to a vent position, and fluid present in the bore 10b housing the lock pin 42, the metered slot 20d and the chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 vent to sump. With the fluid from the bore 10b housing the lock pin 42 draining to sump, the lock pin spring 43 biases the lock pin body 46 towards engagement with the recess 53 in the housing 12, and when the lock pin 42 is alignment with the recess 53 in the housing, the lock pin 42 is moved to a locked position in which the housing 12 is locked relative to the rotor 10. With the fluid in the chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 venting to sump, the force of the spring 23 is greater than the force of the fluid in the chamber 64 on the second end 20e of the spool 20, and the spool 20 moves away from the front plate 43.

With the spool moving towards the fully back position, the metering slot 20b is aligned with the third retard port 127, the first retard annulus 127a, and the first retard port 132a, and the retard chamber annulus 37b connecting the metered slot 20b to the retard passage 35 leading to the retard chamber 5, and the common port 131 and common annulus 130. With the spool 20 moving towards the fully back position, metering slot 20c is aligned with the third advance port 129, the first advance annulus 129a, and the first advance port 128a and advance chamber annulus 37a, connecting the metered slot 20c to the advance passage 33 leading to the advance chamber 3.

With the spool 20 moving towards the fully back position, fluid from the retard chamber 5 flows through retard passage 35 in the rotor 10 through retard chamber annulus portion 37b in the inner shaft 4 to the metered slot 20b on the spool 20 to the third retard port 127a and the common port 131. Fluid is prevented from entering the first retard annulus 127a by check valve 136. From the common line port 131, fluid enters the common annulus 130 and annulus 119. From the annulus 119, fluid flows through the second advance port 128b, into chamber 150a of the second thrust cap 150 and through the first advance port 128a, into the first advance annulus 129a, through check valve 134, through the third advance port 129 and into metered slot 20c. From the metered slot 20c, fluid flows into the advance chamber annulus 37a in the inner shaft 4 to the advance passage 37 in the rotor 10 to the advance chamber 3, moving the vane 10a in the direction show by the arrow in FIG. 17. Fluid is prevented from exiting the advance chamber 3 by the advance check valve 134. Fluid is prevented from flowing back to the pressurized source through inlet passage 118 by check valve 122. Fluid from annulus 119 that flows through the third retard port 127, through the first retard annulus 127a and check valve 136 and the first retard port 132a and into chamber 149a of the first thrust cap 149 will flow through the retard check valve 136 and into the metered slot 20b leading back to the annulus 119 and to the retard chamber 3. Fluid is supplied to the phaser by inlet line 118 from a pressurized source (not shown) to make up for leakage only.

FIGS. 20-22 show a mid position. In the mid position, the force on the first end of the spool 20 by the spring 23 equals the force of the fluid in chamber 64 on the second end 20e of the spool 20, such that the metered slot 20c is open to the first advance port 128a, the first advance annulus 129a and the third advance port 129 and advance chamber annulus portion 37a leading to the advance passage 33 and the advance chamber 3 and metered slot 20b is open to the first retard port 132a, the first retard port annulus 127a and retard port 127 and retard chamber annulus portion 37b leading to the retard passage 35 and the retard chamber 5. Makeup oil is supplied to the phaser 70 from a pressurized source (not shown) to make up for leakage and enters line 118 in the first bearing 147. From the inlet line 118, fluid enters annulus 119 formed between the outer shaft 2 and the inner shaft 4 and enters the second advance port 128b and chamber 150a of the second thrust cap 150, through the first advance port 128a, the first advance annulus 129a and the advance check valve 134 and the advance port 129 to metered slot 20c of the spool 20 which leads to the advance chamber annulus portion 37a and advance passage 33 leading to the advance chamber 3. The fluid from annulus 119 between the outer and inner shafts 2, 4 also enters the second retard annulus 132b and chamber 149a of the first thrust cap 149, through the first retard port 132a, the first retard annulus 127a and the retard check valve 136 and the retard port 127 to the metered slot 20b of the spool 20 which leads to the retard chamber annulus portion 37b and the retard passage 35 leading to the retard chamber 5. Fluid is prevented from exiting the common line annulus 130 or port 131 by the spool 20.

Fluid is also directed through the second passage 152 in the second bearing 151 to a groove 60 formed within the outer shaft 2 between the outer shaft 2 and the inner shaft 4 by valve 62. From the groove 60, fluid flows through an annulus 4a in the inner shaft 4 into metered slot 20d that extends a substantial length of the spool 20, however not the entire length of the spool, with one end of the metered slot 20d open to chamber 64 formed between the second end 20e of the spool 20 and the alignment plug 50 and the other end aligned with passage 47 in the rotor 10 leading to the lock pin 42. With the spool in the mid position, fluid flows from the valve 62, through groove 60 and metered slot 20d to passage 47 in the rotor 10, biasing the lock pin body 46 against the lock pin spring 44 moving the lock pin 42 to an unlocked position.

Alternatively, the thrust caps in the second embodiment may be bearings, part of the back plate of the phaser, or any part on the outer shaft.

Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.

Claims

1. A camshaft assembly for an internal combustion engine comprising:

a hollow outer shaft 2 with annuluses 60, 19, 28, 30, 32 along a length of the shaft; an inner shaft 4 having ports 4a, 29, 31, 27 and at least one annulus 37a, 37b along a length of the inner shaft 4 and forming a bore 4a at one end of the inner shaft 4;

the inner shaft 4 received within the hollow outer shaft 2, such that at least a few of the ports 29, 31, 27 along the length of the inner shaft 4 are aligned with the annuluses 28, 30, 32 along the length of the outer shaft 2;

at least one cam lobe 6, 8 directly attached to the outer shaft 2 and at least one other cam lobe directly attached to the inner shaft 4;

a phaser 70 comprising: i) a housing 12 an outer circumference 14 for accepting a drive force; ii) a rotor 10 coaxially located within the housing 12, the housing 12 and the rotor 10 defining at least one vane 10a separating a chamber in the housing into advance and retard chambers 3, 5, the vane 10a being capable of rotation to shift the relative angular position of the housing 12 and the rotor 10; and iii) a control valve 21 received within the bore 4c of the inner shaft 4 comprising a spool 20 with a plurality of metered slots 20b, 20c, 20d;

at least one bearing 49 adjacent to the second cam lobe 6 and the housing 12 of the phaser 70 on the outer shaft 4 having a first passage 18 connected to a pressurized source for providing makeup oil to the phaser and a second passage 52 in fluid communication with a valve 62 for controlling the position of the spool of the control valve 21.

2. The camshaft assembly of claim 1, wherein the second passage 52 in the at least one bearing provides fluid to a metered slot 20d of the spool and controls position of a lock pin.

3. A camshaft assembly for an internal combustion engine comprising:

a hollow outer shaft 2 with annuluses 60, 19, 28, 30, 32 along a length of the shaft; an inner shaft 4 having ports 4a, 29, 31, 27 and at least one annulus 37a, 37b along a length of the inner shaft 4 and forming a bore 4a at one end of the inner shaft 4;

the inner shaft 4 received within the hollow outer shaft 2, such that at least a few of the ports 29, 31, 27 along the length of the inner shaft 4 are aligned with the annuluses 28, 30, 32 along the length of the outer shaft 2;

a first set of cam lobes fixed to the outer shaft 2;

a second set of cam lobes defining a hole, placed on the outer shaft 2 such that the hole is aligned over the slots on the outer shaft 2 with a clearance fit; and a means for fixing the second set of cam lobes to the inner shaft 4, while simultaneously allowing the second set of cam lobes to clearance fit to the outer shaft 2;

a phaser 70 comprising: i) a housing 12 an outer circumference 14 for accepting a drive force; ii) a rotor 10 coaxially located within the housing 12, the housing 12 and the rotor 10 defining at least one vane 10a separating a chamber in the housing into advance and retard chambers 3, 5, the vane 10a being capable of rotation to shift the relative angular position of the housing 12 and the rotor 10; and iii) a control valve 21 received within the bore 4c of the inner shaft 4 comprising a spool 20 with a plurality of metered slots 20b, 20c, 20d;

at least one bearing 49 adjacent to the second cam lobe 6 and the housing 12 of the phaser 70 on the outer shaft 4 having a first passage 18 connected to a pressurized source for providing makeup oil to the phaser and a second passage 52 in fluid communication with a valve 62 for controlling the position of the spool of the control valve.

4. A camshaft assembly for an internal combustion engine comprising:

a hollow outer shaft 2 with annuluses 60, 19, 28, 30, 32 along a length of the shaft; an inner shaft 4 having ports 4a, 29,31, 27 and at least on annulus 37a, 37b along a length of the inner shaft 4 and forming a bore 4a at one end of the inner shaft 4;

the inner shaft 4 received within the hollow outer shaft 2, such that at least a few of the ports 29, 31, 27 along the length of the inner shaft 4 are aligned with the annuluses 28, 30, 32 along the length of the outer shaft 2;

at least one cam lobe 6, 8 attached to the outer shaft 2 and at least one other cam lobe attached to the inner shaft 4;

a phaser 70 comprising: i) a housing 12 an outer circumference 14 for accepting a drive force; ii) a rotor 10 coaxially located within the housing 12, the housing 12 and the rotor 10 defining at least one vane 10a separating a chamber in the housing into advance and retard chambers 3, 5, the vane 10a being capable of rotation to shift the relative angular position of the housing 12 and the rotor 10; and iii) a control valve 21 received within the bore 4c of the inner shaft 4 comprising a spool 20 with a plurality of metered slots 20b, 20c, 20d;

a first outer shaft piece 149 adjacent to the housing 12 of the phaser and a first bearing 147; the first outer shaft piece 149 defining a chamber 149a for fluid to flow to and from the retard chamber 5 through the metered slot 20b on the spool 20; the first bearing 147 having a passage 118 connected to a pressurized source for providing makeup oil to the phaser 70;

a outer shaft piece 150 adjacent to the first bearing 147 and the second cam lobe 6 defining a chamber 150a for fluid flow to and from the advance chamber 3 through the metered slot 20c on the spool 20;

a second bearing 151 comprising a passage 152 in fluid communication with a valve 62 for controlling the position of the spool of the control valve.

5. The camshaft assembly of claim 4, wherein the passage in the second outer shaft piece provides fluid to metered slot 20d of the spool and controls lock pin position.

6. The camshaft assembly of claim 4, wherein the at least one cam lobe is directly attached to the inner shaft and the at least one other cam lobe is directly attached to the outer shaft.

7. The camshaft assembly of claim 4, wherein the at least one cam lobe is a first set of cam lobes fixed to the outer shaft: and the at least one other cam lobe is a second set of cam lobes defining a hole, placed on the outer shaft 2 such that the hole is aligned over the slots on the outer shaft 2 with a clearance fit; and a means for fixing the second set of cam lobes to the inner shaft 4, while simultaneously allowing the second set of cam lobes to clearance fit to the outer shaft 2.