Patent Application
20170101929
The present disclosure relates to systems and methods for the manufacture of engines.
Engine manufacturing is a complex and expensive process in view of the number of parts involved and the precision required to manufacture an engine block, particularly in substantial quantities. For example, an engine block for an engine may be manufactured by a casting process. In order to produce the block in significant quantities, casting molds may be created and manufacturing equipment may be configured to process the casting molds through the casting process. Accordingly, changing the displacement of an engine associated with the engine block generally requires re-designing or modifying a significant number of parts and may also require production of new molds as well as reconfiguration of complex manufacturing equipment configured to process the molds.
Various embodiments provide methods of varying engine displacement and internal combustion engine assemblies configured to permit such varying displacement.
In particular embodiments, a method of varying a displacement of an engine is provided that includes determining a change in a stroke distance of the engine required to obtain a pre-determined volumetric change in a displacement of the engine. The method includes machining a top surface of a crankcase so as to remove a height of material from the crankcase. The height is calculated to correspond to the change in the stroke of the engine required to obtain the volumetric change in the displacement of the engine. The method also includes coupling the crankcase to an engine block portion of the engine.
In particular embodiments, the engine block portion is integrally formed with a cylinder head portion. The method includes coupling a valve cartridge assembly to the cylinder head portion of the engine block portion, in accordance with particular embodiments. The valve cartridge assembly includes a cartridge housing including a port and a valve seat defining a valve seat opening. A valve is coupled to the cartridge housing and positioned, in part in the cartridge housing. The valve includes a valve stem and a valve head. The valve head is positioned in the valve seat of the cartridge housing in a closed configuration and the valve head extends out of the valve seat opening in an open configuration. The valve cartridge assembly includes a valve spring coupled to the cartridge housing and the valve stem of the valve, biasing the valve towards the closed configuration. In particular embodiments, coupling the valve cartridge assembly to the cylinder head portion includes inserting the valve cartridge assembly into a cartridge slot at the head portion through a cylinder opening of the engine block portion.
In particular embodiments, a valve cartridge assembly is provided that includes a cartridge housing including a port and a valve seat defining a valve seat opening. A valve is coupled to the cartridge housing and positioned, in part in the cartridge housing. The valve includes a valve stem and a valve head. The valve head is positioned in the valve seat of the cartridge housing in a closed configuration and the valve head extends out of the valve seat opening in an open configuration. The valve cartridge assembly includes a valve spring coupled to the cartridge housing and the valve stem of the valve, biasing the valve towards the closed configuration. The valve cartridge assembly may include a spring retainer coupling the valve spring to the valve stem. The cartridge housing fluidly couples the valve seat opening to the port, in accordance with particular embodiments.
In particular embodiments, an engine assembly is provided that includes an engine block including an engine block portion integrally formed with a cylinder head portion. The engine block portion includes a plurality of cylindrical cylinder block openings and a first mating surface. The engine assembly includes a crankcase coupled to the engine block portion. The crankcase may include a second mating surface comprising a crankcase extension, the crankcase extension configured for removal from the crankcase to change a displacement of the engine assembly. In particular embodiments, a valve cartridge assembly is coupled to the cylinder head portion of the engine block. The valve cartridge assembly includes a cartridge housing including a port and a valve seat defining a valve seat opening. A valve is disposed in the cartridge housing, the valve including a valve stem and a valve head, the valve head. The valve head is positioned in the valve seat in a closed configuration and the valve head extends out of the valve seat opening in an open configuration. The valve cartridge assembly includes a valve spring coupled to the cartridge housing and the valve stem of the valve, biasing the valve towards the closed configuration.
It should be appreciated that all combinations of the foregoing concepts and additional concepts discussed in greater detail below (provided such concepts are not mutually inconsistent) are contemplated as being part of the inventive subject matter disclosed herein. In particular, all combinations of claimed subject matter appearing at the end of this disclosure are contemplated as being part of the inventive subject matter disclosed herein.
The skilled artisan will understand that the drawings primarily are for illustrative purposes and are not intended to limit the scope of the subject matter described herein. The drawings are not necessarily to scale; in some instances, various aspects of the subject matter disclosed herein may be shown exaggerated or enlarged in the drawings to facilitate an understanding of different features. In the drawings, like reference characters generally refer to like features (e.g., functionally similar and/or structurally similar elements).
The features and advantages of the inventive concepts disclosed herein will become more apparent from the detailed description set forth below when taken in conjunction with the drawings.
Following below are more detailed descriptions of various concepts related to, and embodiments of, varying engine displacement and various internal combustion engine components. It should be appreciated that various concepts introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the disclosed concepts are not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.
The cylinder head portion is configured to house a plurality of intake and exhaust valves, and to couple those valves to an intake manifold and an exhaust manifold, respectively. Being of a single monolithic construction, the combined cylinder head and cylinder block portion 101 eliminates the need for a head gasket (i.e., that may otherwise be needed at a block-head junction), thereby permitting higher peak cylinder pressures. The combined cylinder head and cylinder block portion 101 may be manufactured by casting, in accordance with example embodiments. In particular embodiments, the combined cylinder head and cylinder block portion 101 may be composed, in part, or in whole, of one or more of grey iron and aluminum.
The crankcase portion 102 houses a crankshaft, and is configured for variation in the displacement of the engine assembly 100. For example and in one specific implementation, the engine assembly 100 may have an initial displacement of 3.9 L based on the quantity and diameter of the plurality of cylinders 103 and the stroke length permitted by the crankcase portion 102 for pistons, piston rods, and connecting rods coupled to the crankshaft housed in the crankcase portion. In order to reduce the 3.9 L displacement, a top surface of the crankcase portion 102 (i.e., configured to serve as a mating surface of the crankcase portion 102, to engage the combined cylinder head and cylinder block portion 101) may be machined, for example removing a 5 mm layer of the crankcase portion 102. In one implementation, removing the 5 mm layer of the crankcase portion 102 effectively raises a crankshaft disposed within by a corresponding 5 mm towards the combined cylinder head and cylinder block portion 101, thereby reducing displacement across all cylinders 103.
In one implementation, the top surface of the crankcase portion 102 may include a 5 mm crankcase extension casted into the crankcase during manufacture. The crankcase extension permits optional machining of the top layer such that the machined crankcase is configured to matingly engage a cylinder block portion bottom surface 104 of the combined cylinder head and cylinder block portion 101. Alternatively, in the same manner, an unmachined crankcase can engage the cylinder block portion bottom surface 104. In other words, the crankcase extension may be removed in varying degrees (e.g., where the crankcase extension is 5 mm high, by any height ranging from 0 mm to 5 mm, depending on a desired displacement reduction) and then engaged to the combined cylinder head and cylinder block portion 101.
A machined crankcase may be fitted with a new crankshaft or crankshaft assembly to accommodate a shorter stroke length caused by the removal of the crankcase extension. For example, the dimensions of a crankshaft configured to operate with a full crankcase extension (i.e., where none of the crankcase extension is removed) may conflict with an engine assembly with the crankcase extension removed. In some arrangements, a crankshaft may be selected to further reduce the stroke volume within the cylinders 103, thereby reducing the displacement further. For example, a first crankshaft having a larger first rotational circumference can in operation cause associated rods and pistons to travel along a longer stroke distance. In turn, a replacement second crankshaft having a smaller rotational circumference can in operation cause associated rods and pistons to travel along a shorter stroke distance. As such, in addition to machining the crankcase extension, the crankshaft may be replaced with one having a smaller rotational diameter to effectively reduce the displacement of an engine assembly.
The valve cartridge assembly 400 includes a valve spring 407 coupled to the valve stem 406 of the valve 404. In particular embodiments, the valve spring 407 is coupled to the valve stem 406 via a spring retainer 408 and a valve collate 409 at the proximal end 410. The spring retainer 408 and the valve collate 409 retain the valve spring 407 between the valve stem 406 and the cartridge housing 401 through which the valve stem 406 extends. In some embodiments, at least one of the spring retainer 408, the valve collate 409, and the cartridge housing 401 is configured to restrict the lateral movement of the valve 404 (i.e., such that the valve 404 is substantially restricted to two-directional movement). For example, the cartridge housing 401 may include a guide channel 411, which is an aperture along a center axis 412 in the cartridge housing 401, extending from the intake/exhaust port opening 403 up and through the proximal end (i.e., towards the proximal end 410) of the cartridge housing 401. The guide channel 411 is just large enough in diameter to accommodate the diameter and a length of the valve stem 406, disposed therein. As such, the valve 404 may translate up and down along the center axis of the cartridge housing 401 in the guide channel 411, but may not appreciably translate radially or laterally from the center axis.
In some arrangements, the valve cartridge assembly 400 includes a plurality of valves 404. For example, a single cartridge housing 401 can include a corresponding one intake/exhaust port opening 403, one valve seat opening 402, one guide channel 411, and so on, for each of a plurality of valves 404. As such, a given valve cartridge assembly 400 can be a single unit comprising a plurality of intake and/or exhaust valves.
In operation, the valve 404 is movable within the cartridge housing 401 from a seated position (closed) wherein the valve head 405 is positioned on the valve seat to an unseated position (open) wherein the valve head 405 extends out of the valve seat opening 402 (i.e., away from the cartridge housing 401). In the seated positioned, the valve head 405 is positioned in the valve seat to prevent fluid communication between the valve seat opening 402 and the intake/exhaust port opening 403. In the unseated position, the valve stem 406 of the valve 404 extends into the valve seat opening 402, thereby lifting the valve head off the valve seat and permitting fluid communication between the intake/exhaust port opening 403 and the valve seat opening 402.
To open the valve cartridge assembly 400 (i.e., to transition the valve 404 from the seated position to the unseated position), an actuator such as a cam on an intake or exhaust camshaft applies force against the proximal end 410 of the valve stem 406. The force moves the proximal end 410 of the valve stem 406 with respect to the cartridge housing 401 and thereby compresses the valve spring 407. As the proximal end 410 of the valve stem 406 is moved closer to the cartridge housing 401, the valve cartridge assembly 400 is opened as the valve head 405 is unseated from the valve seat at the valve seat opening 402. When the valve cartridge assembly 400 is opened it allows intake air to flow through the cartridge housing 401 and into a combustion chamber of an engine cylinder of an engine housing the valve cartridge assembly or permits exhaust air to flow through the cartridge housing 401 from the engine cylinder. When the actuation force applied by the cam is removed, a biasing force from the compressed valve spring 407 pushes the valve 404 back into the seated configuration closing the valve cartridge assembly 400 as the valve head 405 is re-seated in the valve seat opening 402.
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For the purpose of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary or moveable in nature. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or may be removable or releasable in nature.
It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure. It is recognized that features of the disclosed embodiments can be incorporated into other disclosed embodiments.
It is important to note that the constructions and arrangements of apparatuses or the components thereof as shown in the various exemplary embodiments are illustrative only. Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter disclosed. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present disclosure.
While various inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other mechanisms and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein. More generally, those skilled in the art will readily appreciate that, unless otherwise noted, any parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein. It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto, inventive embodiments may be practiced otherwise than as specifically described and claimed. Inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.
Also, the technology described herein may be embodied as a method, of which at least one example has been provided. The acts performed as part of the method may be ordered in any suitable way unless otherwise specifically noted. Accordingly, embodiments may be constructed in which acts are performed in an order different than illustrated, which may include performing some acts simultaneously, even though shown as sequential acts in illustrative embodiments.
The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.”
In the claims, as well as in the specification above, all transitional phrases such as “comprising,” “including,” “having,” “involving,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to.
The claims should not be read as limited to the described order or elements unless stated to that effect. It should be understood that various changes in form and detail may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. All embodiments that come within the spirit and scope of the following claims and equivalents thereto are claimed.
This application claims priority and the benefit of U.S. Provisional Patent Application No. 62/017,496, entitled “ENGINE CONFIGURATION HAVING VARIOUS DISPLACEMENTS,” filed on Jun. 26, 2014, the entire disclosure of which is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2015/037696 | 6/25/2015 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62017496 | Jun 2014 | US |
