In this paper we present new hydraulic valve systems designed for the application in hydraulic roll control systems of passenger cars. An overview of hydraulic architectures already in use is given. For a standard solution with pressure control and directional valves remarkable improvements of the dynamic response have been realised by optimisation of valve damping. An entirely novel 4/3 pressure reducing valve enables pressure control in both actuator volumes. The variety of simulation and test methods used on component and system level is presented. Furthermore we describe design and fabrication of key functional parts and newly developed assembly processes under the conditions of mass production. The development of functional and primary parts took place simultaneously to the conception of a mostly automated assembly line. The pressure-loaded valve tubes are consequently realised as laser welding designs whereas also deep-drawing or cold extrusion parts are connected pressure-tightly. These assembly steps, except the steps of insertion and withdrawal of parts, happen fully automatic. Furthermore, an automated pressure tightness check has been integrated to enable a 100% check of the welded assemblies - cycle-time neutral. During assembly of 4/3 valves adjusting processes have been designated both for the production of linear motors as well as the production of the complete valves. This allows the use of lower precision parts, as tolerance variations can be compensated by these adjusting processes. Regarding the linear motor, for example, the force level of the drive is measured and the appropriate spring combination to stabilise the drive is selected based on this measurement. The centre position of the armature inside the drive is then adjusted through a calibration process that occurs purely on "press-to-position" by an adjustment element. In case of the 4/3 valve, the hydraulic adjustment of the valve piston to the magnetic drive is fully automatic in the final check. In this case, the hydraulic pressure-current-characteristic is measured and the piston is afterwards changed in its position until the desired characteristic is present. Then, the control piston is automatically fixed in this position.
Further development of valve technology in vehicle's hydraulic roll control systems
2014
11 Seiten, Bilder, 3 Quellen
Conference paper
English
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