Tao Xu, Chungyao Tang, Huihua Shen,

Michael King, Mark Nowak

Ford Motor Company
Adams Modeling Tool Development of
OHV Pushrod Bridged Valve Train
Presentation number 2007-32
Introduction AP, VEE

• The purpose is to support OHV pushrod VT design of

a diesel engine program.

• The bridged valve train CAE tool was developed and

is based on Adams/View simulation environment:

. 3D elephant foot-bridge-valve interaction module

. Equivalent stiffness for bridge, rockers and fulcrum mount, etc..
. Multi-mass valve spring
. Detailed analytical hydraulic tappet model
. In-cylinder and valve back pressures
. Many contact forces with manufacturing clearance consideration
……
Modeling Based on Adams AP, VEE

Beam-like
pushrod

OHV pushrod bridged valve train

Modeling Based on Adams AP, VEE

Beam-like
pushrod Hydraulic tappet
Multi-mass dp β ⎛ dV ⎞
= − ⎜ − ∑ Q in + ∑ Q out ⎟
springs dt V ⎝ dt ⎠

Clearance
between valve Contact force Roller
and bridge,
and guide

Cam shaft
ValveContact
stem forces stiffness and
and guide bearing with
Cam motion clearance

In-cylinder and port pressures are applied to the valves

Modeling Based on Adams AP, VEE

dP β dV dV dV dV
Action load = − * ( vol + leakdown + valve + hole ) (1)
dt V dt dt dt dt
Piston

Where P = pressure in high pressure chamber

Hole β = effective bulk modulus
Low pressure chamber
Housing V = volume of fluid in high pressure chamber

Supply Check ball

oil 2
(Phigh−chamber / P0 )
β= * (1+ f AE ) * β0 (2)
Leakdown Retainer &
/ P0 ) + f AE * β0
2
distance check ball (P
high−chamber
retaining spring

High pressure chamber Where P0 = supply oil pressure

Expansion β0 = bulk modulus of oil at atmospheric pressure

spring
fAE = the fractional aeration of oil in high pressure
Reaction Force
chamber

Hydraulic Tappet (Lash Adjuster)

Modeling Based on Adams AP, VEE

Valve Spring Force – Spring Surge Effect Multi-Mass Spring Model

No Surge
Physical Discretized
Spring Model
mi = ρA2πΔNiri
mi-1 ItG
ki = cosαi
2πri ΔNi
3

Surge (Helical Compression Spring)

mi
y
⎛ k ⎞
Preload compression is lost due to
Fclashi =kclashi ⎜⎜di−1 −di +s −X⎟⎟
surge; here to ½ the original value. mi+1 ⎝ ki ⎠
Schamel, et. al., SAE Intl. Congress, 1993

Multi-mass Valve Spring

Validation AP, VEE

Exhaust pushrod
load

Intake pushrod
load
Pushrod
Load

Valve back
Pressure Crank Angle

Pushrod load correlation at a medium engine speed with full load

Validation AP, VEE

Exhaust pushrod
load
Intake pushrod
load

Pushrod
Load

Valve back
Crank Angle
pressure

Pushrod load correlation at a high engine speed with light load

Design Analysis AP, VEE

• The simulation tool has been used to drive one

bridged valve train design of diesel engine
program on:
. System frequency identification
. Spring surge check
. Max. valve seating velocity improvement
. Max. pushrod loads and no-follow speed prediction
. Valve motion variation stability due to valve guide
clearance and valve spring rate variation
Design Analysis AP, VEE

Intake

Exhaust

Bridged valve train natural frequency

Design Analysis AP, VEE

4.0
LB int.
LB exh
3.5 LB exh 20% stiffer Total exhaust
Exhaust valve
Seating Velocity (m/sec)

3.0 seating velocity VT stiffness

is increased
2.5

2.0

1.5

1.0 Gasoline engine

Durability durability
Design Spec.spec.

0.5
Intake valve
0.0 seating velocity
0 1000 2000 3000 4000 5000 6000

Engine Speed (rpm)

Valve seating velocity improvement

Design Analysis AP, VEE

5000 500
max LB int. Max pushrod/ tappet
4500
max. LB exh load due to gas pressure

Min. cam contact force (N)

4000 min LB int 400
Max. cam contact force (N)

3500
min LB exh

3000 60% increased 300

2500

2000 200
Motoring
1500 pushrod/ No-follow speed
1000
tappet loads 100

500

0 0
0 1000 2000 3000 4000 5000 6000

Engine Speed (rpm)

Max. pushrod/tappet loads and no-follow speed prediction

Design Analysis Animation AP, VEE

Bridged valve train animation at an engine speed with full load

Conclusion AP, VEE

• A high-fidelity OHV bridged valve train CAE

tool based on Adams has been developed
and validated by measurement.

• The analytical results have greatly contributed

to the bridged valve train design improvement.
Tao Xu
Email: txu@ford.com Tel. +313 337 1895