ZHEJIANG MASTER INJECTION SYSTEM CO.,LTD
VVT项目介绍
Hydraulic VVT Introduction
1. VVT 项目开发历程 VVT Develop History
量产清单Massproductionlist
主机厂Factory OE.
01
02
03 福特Ford 917-250 征服者、探险者、野马、登山者
04 雪佛兰Chevrolet 917-254 探界者、科沃兹、君越、君威
05
福特Ford、路虎Landrover CJ5E6C524AE 蒙迪欧、致胜、发现
奔驰Benz 2710500800 梅赛德斯 奔驰 Mercedes-BenzC-Class2003-2011款 /C-ClassT-Model2003-2011款 /CLK2003-2010款 /E-
CLC-Class2008-2011款 /CLK2004-2010款 /E-Class2005-2016款 /E-ClassT-Model2005-2011款 /G-Class2008-2020款 /G-Class Cabrio2009-2020款
/2
款 /3GranTurismo2012-2016款 /3Series2011-2018 款 /4Gran2014-2020款 /4Series2013-2020款 /5Series2010-2017款 /5SeriesGranTurismo2013-2017 款 /X12011-2015款 /X32011-2017款 /X42014-2018款 /X5
奔驰Benz 2700506100 梅赛德斯 奔驰 Mercedes-BenzA-Class2012-2018款 /B-Class2011-2018款 /C-Class2015-2018款 /C-ClassTModel2015-2019款 /CLA2013-2019款 /CLAShootingBrake2015-2019款 /GLA-Class2013-2019款
VVTTraditionalVVT
2.
传统铝合金叶片式
Traditional aluminum vane H-VVT
⚫基本功能、性能实现
Achieve basic function, performance
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粉末冶金叶片式H-VVT
Powder metal vane
⚫更高的可靠性,更好的性能指标
Higher reliability, better performance
E-VVT
⚫更大的可调节角度
Bigger shifting angle
⚫更宽的可标定区间
Wider calibration range
HM-VVT
⚫更好的性能指标 Better performance
⚫更低的发动机综合成本
Lower engine whole cost
HMM-VVT
⚫更大的可调节角度
Bigger shifting angle
⚫阿特金森循环
Atkinson cycle
HIE VVT(High Intelligent Efficiency)
⚫更快的响应 Faster response ⚫更低的发动机油耗
Lower oi l consumption
传统VVT 简介Introduction to HM-VVT
滞后调节
OCVpoweredon,exhaustVCPadjustedtolagdirection
提前调节 advance
Return Valve 1A Valve 0A
OCVpoweroutage,exhaustVCPadjustedtoadvancedirection
Development of VVT product structure
HM-VVT 简介Introduction to HM-VVT
进气 Intake VCP
机油控制阀 Oil Control Valve
电磁铁 Magnet
排气 Exhaust VCP
机油控制阀 Oil Control Valve
电磁铁 Magnet
HM-VVT 简介Introduction to HM-VVT
滞后调节 Return
HM-VVT 简介Introduction to HM-VVT
advance Valve 1A
OCVpoweredon,intakeVCPadjustedtoadvancedirection
中置式VVT 性能表现Performance performance of HM-VVT
➢ 提高系统响应速度，尤其是在低转速、低油压和低温工况；
➢ 减少油耗，降低机油泵负荷；
➢ Increasesystemresponsevelocity,speciallyunderlowspeed,lowoilpressure,andlowtemperature
➢ LowoilconsumptionduringVVTshiftingprocess,reduceloadtooilpump.
转速 (RPM) 90 ℃ -Oil saving simulation
VVT 性能表现Performance performance of HM-VVT
Control Stability (Crank Angle)
结论：控制精度满足＜±1°CA.
➢ Conclusion: testresults ＜±1°CA.
3. 产品开发能力 VVT develop capability
设计目标
DesignTarget
产品布局
Productlayout 产品设计
QFD、FTA、Benchmark
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系统分析
CAE,toleranceanalysis
实验设计
DOE
实验计划
Flowchart,benchtest validation
ProductDesign
DFMEA开发
DFMEADevelop
系统组件分析
System&Componentanalysis
DV实验
DVTest
结构尺寸
Boundarydimension
◆System
•TS16949-APQP
◆Standard
•JB/T13289-2017
尺寸、材料、性能
Dimensions,material performance
设计校核、DV清单
Designreview,DVlist
响应、控制、泄漏、强度、应
力Response,accuracy,leakage, strength,stress
功能、耐久性、可靠性
Function,perlorance,reliability
◆CAD
•PRO/E
•UG
•CATIA
•AUTOCAD
◆CAE
•ANSYS
•Maxwell
•Amesim
设计冻结
Designfrozen
◆PLM
Current control and preventive measures
A: Design standards reference table
B:Simulation analysis table
C: Benchmarking table
D: Tolerance analysis table
E: Design calculation sheet
F: Empirical data reference table
Design optimization table
Design frozen 历史失效参考 Historical failure reference
Design record A—Design standard
Design record B Design Simulation
Design record C—Design
Design record D—Design Tolerance Analysis
Design record E—Design calculation
Design record F—Experience data
VVT开发仿真计算
VVTdevelopsimulation
系统响应速度
Systemresponsespeed
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系统控制精度
Systemcontrolstability
VCPParts 机械强度仿真
Mechanicalstrength simulation 扭簧模态仿真
SpringModal simulation
OCVParts 机械强度仿
Mechanicalstrenght
Electromagnetic temperaturesimulation
OCVParts 静态电磁特 性仿真
Staticelectromagnetic simulation 瞬态电磁特性仿真
Instantelectromagnetic simulation
OCVParts 流量特性仿
simulation
Pressureloss simulation
3. 产品开发能力 VVT develop capability
OCV单体试验 OCV Test
阀体总成P-A流量测试
P-Aflowtest
阀体总成P-B流量测试
P-Bflowtest
阀体总成B-A流量测试
B-Aflowtest
阀体总成A-B流量测试
A-Bflowtest
P口单向阀开启压力测试
P-portcheckvalveopeningpressuretest
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P口单向阀反向泄漏测试
P-portcheckvalvereverseleakagetest
循环单向阀开启压力测试
Circulatingcheckvalveopenpressuretest
循环单向阀反向泄漏测试
Circulatingcheckvalvereverseleakagetest
滤网强度验证试验
Filterstrengthtest
螺栓内孔变形量验证试验
BoldInnerholedeformationvalidationtest
泄漏量测试
Leakagetest
线圈电阻测试
Coilresistancetest
绝缘电阻测试
Absoluteresistancetest
循环单向阀耐久试验
Circulatingcheckvalveendurancetest
共42项 Total42items
气密性测试
Airtighttest
螺栓拉断力验证试验
Boltbreakforcevalidationtest
保持点电流测试
Holdpointcurrenttest
响应时间测试
Responsetimetest
异物动作寿命可靠性试验
相位器单体试验 VCP test
锁销解锁油压测试
Lockingpinunlockingoilpressuretest
相位器泄漏量测试
VCPleakagetest
锁销间隙测试
Lockingpinbacklashtest
可调节角度测试
Adjustableangletest
Foreignmatteractionlifereliabilitytest 摩擦扭矩测试
高温动作寿命可靠性试验
Hightempactionliftreliabilitytest
低温动作寿命可靠性试验
Lowtempactionreliabilitytest
冷热冲击试验
Cold-hotimpacttest
抗振动可靠性试验
Vibrationresistancereliabilitytest
耐水可靠性试验 Waterresistancereliabilitytest
耐盐水喷雾试验
Saultsprayresistancereliabilitytest
100H抗化学腐蚀药品试验
100Hchemicalresistancetest
Frictiontorquetest
锁销机构耐转矩强度测试
Lockingmechanismtorqueresistancetest
500H冷热冲击试验
500Hcoldhotimpacttest
转子打滑试验
Rotorsliptest
壳体打滑试验 Housingsliptest
系统试验 System test
VVT系统执行速度MAP试验
VVTsystemshiftingspeedMAPtest
VVT控制稳定性MAP
VVTcontrolstabilityMAPtest
锁销动作可靠性能试验
Lockingpinactionreliabilitytest
锁销解锁试验
Lockingpinunlockingtest
800H微小动作可靠性能试验
800Hmini-actionreliabilitytest
800H全行程动作可靠性试验
800Hfullstrokereliabilitytest
耐脏油可靠性能试验
Oilcontaminationreliabilitytest
3.
试验项目
Testitem
试验标准
Teststandard
试验目的
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Testobjective
试验设备
Testequipment
试验台Testbench ◆ 重点试验项目及设备Key experimental projects and equipment
VVT 发动机模拟实验
VVTenginesimulationexperiment
JB/T13289-2017内燃机 可变气门系统
JB/T13289-2017TechnicalConditionsforVariableValveSystemCamPhaseAdjustersinInternalCombustion Engines
用于评估VVT的工作范围内功能和耐久表现（-30-140℃）
UsedtoevaluatethefunctionalanddurabilityperformanceofVVTwithintheworkingrange(-30-140 ℃)
发动机缸盖倒拖试验台
Enginecylinderheadreversetowingtestbench
Camangledecoder
曲轴编码器Crankshaftangle encoder
Pressuresensor
油检性能测试台
Performancetestbench
Key experimental projects and equipment
缸盖实验台 Cylinderheadtestbench
信号轮实验台
Signalwheeltestbench 耐脏油试验台
Dirtyoilresistancetestbench
耐久实验台 endurancetestbench
平衡试验机 Balancingmachines
冷热冲击实验箱 Cold-hotimpacttestchamber
高温耐久试验台 Hightemperaturedurabilitytest bench
4. 制造过程策划 VVT Process manufacturing
产品制造主流程图Product Manufacturing Mainstream Process Diagram
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Chemical composition
Mechanicalproperty
Dimensions
Heattreatspec
Cleanliness
Shifting
Unlocking
Key Process Control -
Double End Grinding of Rotors
关键过程控制Key Process Control -VCP性能检测VCP performance test bench
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测试界面Testinterface
VCP性能测试台 Performancetestingbench
序号No. 要求 Requirement
检测方法 Inspection method
控制方法 Control method 1
解锁压力 Unlockingpressure
压力传感器 Pressuresensor
2
3
可调节角度 Shiftingangle
角度编码器 Angledecoder
4
锁销间隙 Lockingpinbacklash
角度编码器 Angledecoder
•100%在线检测100%continuous inspection
•不合格品隔离NOKpartrejected automatically
•启动设备前标Equipmentselfinspectionwhenstart
•传感器定期标校Sensorcalibratedat regulartime
摩擦力矩 Frictiontorque
扭矩传感器 Toquesensor
5 泄漏量Leakage
流量传感器 Flowsensor
•数据记录储存Datastorage
基本性能测试Performancetest
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序号 No. 项目 Item
技术要求 Requirement
1
中心点匹配 Centerpoint matching
工艺设定值 Drawing requirement
2 气密性 Airtightness
OCV性能测试台 OCVperformancetestbench
3 单向阀测试 Checkvalvetest
工艺设定值 Drawing requirement
检测方法 Inspection method
流量传感器 Flowsensor
测试界面Testinterface ◆ 关键过程控制Key Process Control – OCV性能测试仪OCV performance test bench
流量传感器 Flowsensor
工艺设定值 Drawing requirement
4 流量特性 Flowcharacteristics
工艺设定值 Drawing requirement
流量传感器 Flowsensor
控制方法 Control method
•100%在线检测 100%continuous inspection
•不合格品隔离NOK partrejected automatically
•启动设备前标 Equipmentselfinspectionwhen start
•传感器定期标校 Sensorcalibratedat regulartime
•数据记录储存Data storage
流量传感器 Flowsensor
基本性能测试Performancetest
VVT key point process control
电磁阀防卡滞工艺控制Electromagnetic valve anti jamming process control
OP30： ● 精车内孔
OP40：
OP20：
车削外圆 余量：0.024
：
：
• 换向杆毛刺控制工序Controlprocessforburrsonthereversingrod：
OP50/OP60/OP80/OP100
• 换向杆高点/碰伤控制工序Controlprocessforhighpoints/bumpson thereversinglever：OP100
• 换向杆清洁度Cleanlinessofthereversinglever ：内部清洁度控制
Internalcleanlinesscontrolprogram
毛刺控制关键工序
Key processes for burr control
OP120：
OP110：
2-7μm
◆ 相位器防卡滞工艺控制
Process control for anti jamming of phase
毛刺控制关键工序
Key processes for burr control
OP40：
• 转子毛刺控制工序Rotorburrcontrolprocess： OP80/OP90/OP100
• 去除倒角毛刺Removeburrsfromchamfers
• 转子清洁度Cleanlinessoftherotor：内部清洁度控制 Internal
cleanlinesscontrolprogram
清洁度控制程序Cleanliness control program
➢需清洗件
Cleaning required
➢外购不清洗件
Purchased non cleaning parts
检清洁度
Cleanliness testing
清洗工序 Cleaning
•多频超声 Multifrequency ultrasound
•分槽分段Dividing slots andsegments
•循环过滤Circular filtration
•专用工装Special tooling
➢包装盒 packing box
•防运输过程中与产品摩
检清洁度 Cleanliness testing
除尘除静电 Dust removal&static electricity
•除静电Removing staticelectricity
•吹吸尘Blowingand vacuuming
•专用通道Dedicated channel
•针对包装For packaging
装配工序 Assembly 包装工序 package
•封闭车间Closed workshop
•气源过滤Airsource filtration
•线体吸尘Vacuum cleaning
•专用器具Special equipment
•封闭车间Closed workshop
•包装吸尘packaging vacuumcleaning
•封闭后出车间Exit theworkshopafter closure
封闭环境 enclosed environment
检清洁度 Cleanliness testing
repair
•·Designtoprevent impuritiesgeneratedby frictionwithproducts duringtransportation
privatechannel
Changing shoesand clothes
airshower
Packaging and shipping
VVT key point process control
相位器防卡滞工艺控制Process control of phase shifter anti jamming
转子超声波清洗过程控制rotor ultrasonic cleaning process control
● 手工清洗
Manualcleaning
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产品独立放置，手工粗洗The productisplacedindependently andhandwashedroughly
● 摆放整齐 Arrangeneatly
产品独立放置 Productindependentplacement
● 粗洗 Roughwashing
180S大杂质粗洗180Scoarse cleaningwithlargeimpurities
● 浸防锈油 Immersionin rustproofoil
进行浸泡防锈油处理 Soakinantirustoiltreatment
● 再粗洗 Furtherrough washing
180S二次粗洗残留较大杂质180S secondaryroughwashingresidual largeimpurities
● 高温烘烤 Hightemperature baking
600S去除产品水分 600Storemoveproductmoisture
● 漂洗 Rinsing
180S漂洗
180Srinse
● 发泡精洗 Foamwashing
180S精洗 180sfinewashing
Provide
Collect
Provide
Provide
Provide
