Exhaust gas recirculation (EGR) module having sensor integrated into cover (ESM)

A control valve comprising:

• a valve body having an inlet port and an outlet port;
• a valve member moveable supporting within said valve body between open and closed positions, wherein said valve member controls the flow of a fluid medium between said inlet port and said outlet port;
• a diaphragm housing operatively mounted to said valve body and supported by said valve body, said diaphragm housing defines a vacuum cavity in a fluid communication with a source of second pressure and a diaphragm member disposed therebetween and operatively connected to said valve member, said diaphragm member moveable in one direction in response to a negative pressure induced in said vacuum cavity and in an opposite direction in response to a biasing force to move said valve member between said open and closed positions;
• a control cap connected to said valve body;
• a vacuum regulator contained within said control cap and operatively connected to said diaphragm housing, said vacuum regulator operable to control the movement of said valve member between said opened and said closed positions by controlling the negative pressure induced in said vacuum cavity;
• a first conduit disposed partially through said cap, wherein said first conduit has one end operatively connected to said valve body near said inlet port;
• a second conduit disposed partially through said cap, wherein said second conduit has one end operatively connected to said vacuum cavity;
• a sensor having a first tower positioned inside of said first conduit and a second tower positioned inside of said second conduit, wherein said first tower in configured to sense a first characteristic inside of said first conduit and transmit a signal value indicative of said value of said first characteristic, and said second tower is configured to sense a second characteristic inside of said second conduit and transmit a signal value indicative of said value of said second characteristic;
• and
• a seal element molded over said first and second towers to contain said first and second towers within said cap.

A control valve comprising:

• a valve body having an inlet port and an outlet port;
• a valve member moveable supporting within said valve body between open and closed positions, wherein said valve member controls the flow of a fluid medium between said inlet port and said outlet port;
• a diaphragm housing operatively mounted to said valve body and supported by said valve body, said diaphragm housing defines a vacuum cavity in a fluid communication with a source of second pressure and a diaphragm member disposed therebetween and operatively connected to said valve member, said diaphragm member moveable in one direction in response to a negative pressure induced in said vacuum cavity and in an opposite direction in response to a biasing force to move said valve member between said open and closed positions;
• a control cap connected to said valve body;
• a vacuum regulator contained within said control cap and operatively connected to said diaphragm housing, said vacuum regulator operable to control the movement of said valve member between said opened and said closed positions by controlling the negative pressure induced in said vacuum cavity;
• a first conduit disposed partially through said cap, wherein said first conduit has one end operatively connected to said valve body near said inlet port;
• a second conduit disposed partially through said cap, wherein said second conduit has one end operatively connected to said vacuum cavity;
• a sensor having a first tower positioned inside of said first conduit and a second tower positioned inside of said second conduit, wherein said first tower in configured to sense a first characteristic inside of said first conduit and transmit a signal value indicative of said value of said first characteristic, and said second tower is configured to sense a second characteristic inside of said second conduit and transmit a signal value indicative of said value of said second characteristic;
• and
• a seal element molded over said first and second towers to contain said first and second towers within said cap;
• an emission filtration system having a vent tube having a first end connected to said valve body between said intake port and said diaphragm and a second end of said vent tube connected to said cap adjacent said solenoid, a nozzle connected through said cap, wherein said nozzle has an aperture extending to the interior portion of said cap and a first filter contained inside of said cap adjacent said aperture of said nozzle, a second filter positioned adjacent said first filter and one or more atmospheric vents located adjacent said second filter.