Design of Assembly System for an Automobile Idle Valve

Jianshu CAO, Yang LI , Dongcai ZHANG Department of Mechanical Engineering. Beijing Institute of Petro-chemical Technology Beijing , China sun_sky518@126.com
AbstractThe automobile idle valve is essential fittings of automobile. So far the assembly of the automobile idle valve is carried out by manual labor but its efficacy is low labor intensity is huge cost is high. In order to change this backward way of assembling the automobile idle valve by manual labor and to meet the need of automobile quantity developing rapidly in our country because the cost of manual labor becomes higher and higher. Hope by using the system in practice the assembly efficiency of car idle valve is enhanced and production costs reduce. The idea of the design and the principle of the operation are described in this paper as well as the control method. The assembly system is simple easy to operate for the car idle valve assembly with high reliability. Keywords- idle valve;automatic assembly; pneumatic

engine speed is up to 1050 rpm, the valve will stop operating[1-2].At vehicles equipped with air condition system, this valve is also known as speeding up idle valve. Because as the compressor of the air condition system activated, it will generator load on the engine and make the idle speed decrease, then the idle speed control valve will be in action to keep the idle speed stability. The structure of which is as shown in Fig. 1.

I. INTRODUCTION Automobile idle valve has the function of adjusting air intake and throttle percentage. For example, when the vehicle needs to be turn round or in case of shut down, the opening percentage of throttle or the two vent channels at the top of the idle valve may be adjusted greater for increasing air intake. With air intake increased, the pressure in manifold will raise and lead to the voltage increase in pressure sensor, and hence the fuel injection quantity will be increased. Problems resulted from turn around or shut down will be resolved[1-2].However, idle valves are assembled manually at present, which features lower productivity, higher labor intensity and cost. In order to change the dated idle valve assembly method, meet the rapidly increasing demands of China automobile industry and cope with the increasing cost of labor, we decided to research and develop an idle valve assembly system independently and hope to put it into actual production, to improve the idle valve assembly efficiency and reduce production cost. As a result, it will be very meaningful and have a promising market to develop a vehicle idle valve assembly system that enables full automatic or half automatic assembly. II. GENERAL SCHEME DESIGN The idle valve is mounted on the bypass hole of throttle. The valve is operated by the idle controller according to ignition signals. When the engine speed is lower than 750 rpm, the idle valve will be actuated to raise engine speed; when the

Fig. 1. Picture of vehicle idle valve

For the idle valve assembly system, its function is to assemble the back cover of the idle valve onto the engine base.The assembly process is as following: firstly, using the cover fixing hardware, press the back cover onto the engine seat tightly and fix them together; then, punch holes on the engine seat, to punch 3 pin holes (2mm) evenly on each side of the engine base; finally, insert pins into corresponding holes. Following above stated sequence, a idle valve will be assembled onto the engine successfully. The vehicle idle valve assembly system is mainly consisted of support, workbench, punching component, pin stamping component, cover tightening component, pin container, etc. as shown in fig.2.The workbench and punching component is driven by motor; pin stamping component and cover tightening component is driven by air cylinder. III. PNEUMATIC SYSTEM DESIGN FOR THE VEHICLE IDLE
VALVE ASSEMBLY SYSTEM

Except two sets of motor drive systems, the system is totally driven by a pneumatic system, as shown in fig. 4. the cylinder volume is determined according to operating stroke

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and driving force, and the capacity for air pump is determined according to cylinder gas consumption and working beat. As shown in above figure (Fig. 3), with pressing the button 1.1, the single acting cylinder 1.0 will be pushed downwardly, to press the back cover of the idle valve with the engine seat.

Additionally, the cylinder speed at both directions can be adjusted with a one-way throttle valve. The pneumatic control valves on both ends are provided with memory function. Valve will stay at original position until a direction reversing signal received. It is for these reasons that the signal from buttons only requires to last for very short time. The design under this paper shall be operated under manual assisting, which is easy to operation and features excellent operability. Component list is shown as Table 1.
Table 1 Component List Component Single-Acting Cylinder double-Acting Cylinder One-way throttle 5/2 Dual-chamber air reversing valve 3/2 Single-chamber air reversing valve Air supply device (set) Qty 1 2 4 2 5 1 Description To drive the back over tightening component, actuator To drive the centre and electric drill, actuator Speed regulation device; used to regulate the forward speed of double-acting cylinder Changeover the compressor air flow direction of double-acting cylinder To active signal Duplex or triple parts; to supply power source

IV.
Fig.2. Structural view for vehicle idle valve assembly system

DESIGN ANALYSIS FOR CONTROL SYSTEM

After operation, with releasing button 1.1, the air cylinder 1.0 will be back to home position. The working characters of air cylinder 2.0 and 3.0 is similar, here will describe their controlling method together. For facilitate description, only the controlling method for cylinder 2.0 will be described here. The controlling method for cylinder 3.0 is similar to that of cylinder 2. With pushing the button 2.2, the piston of double acting cylinder 2.0 will extend out. The cylinder will maintain at the extending position, until another button 2.3 is pushed and the button 2.2 is released. Now, the cylinder will be back to the home position. The cylinder will maintain at home position until the new start up signal.

The controller will use the CPU224Xp programmable controller by Siemens. Input elements include proximity switches, magnetic switches and LV switches and buttons, which is sued to capture external information, such as position, and input it into the programmable controller and then be output to actuators such as motor, cylinder, etc. The system will control reversing valve, drive cylinder and conduct any required activities according to the control program. V. CONCLUSION

In order to change the dated idle valve assembly method, meet the rapidly increasing demands of China automobile industry and cope with the increasing cost of labor, we researched and developed an idle valve assembly system independently and hope to put it into actual production, to improve the idle valve assembly efficiency and reduce production cost. REFERENCES
[1] Yang Haiyan, the Research of Automotive Engine Idle Speed Control[D]: [Master's Thesis].Tianjin Hebei University of Technology 2007 (In Chinese). Wei Hongming, Combination Modes of Idle Control Valve on Imported Cars[J]. Automotive Electrical Appliances 2003 (3) 37-40 (In Chinese). Chen Jiachao,Dong Yuge, The research and development of an automatic assembly system for automobile lock cores[J]. Mechanical Design and Manufacturing,2008,(8 :197-199 (In Chinese). Pu Lianggui,Ji Minggang. Mechanical Design[M].Beijing:Higher Education Press, 2006 (In Chinese). Wu Weirong. Pneumatic Technology[M]. Beijing:China Light Industry Press 2005.31-132

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[4] [5] Fig.3 Schematic view for pneumatic loop

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