The present disclosure relates to an internal combustion engine including an in-line balance shaft system.
Internal combustion engines are used, for example, by vehicles for propulsion. Alternatively, internal combustion engines may be used to provide power to other devices.
The present disclosure describes an in-line balance shaft system for balancing internal combustion engines. Specifically, the in-line balance shaft system is configured to balance reciprocating internal forces of the internal combustion engine, providing both concurrent and counter-rotating balance forces on the same shaft with less weight than other balance systems (which may be based on two shafts). Other balance systems include distribution mechanisms, such as a chain or a belt. The presently disclosed in-line balance shaft system does not include distribution mechanisms, such as a chain, a belt and/or tensioner. Further, the presently disclosed in-line balance shaft system has both concurrent and counter rotating balancing components on the same axis with a more compact packaging size than other balance systems (e.g., one shaft less) and is an overall lighter system than other balance systems. The presently disclosed in-line balance system may be assembled on a shorter shaft (as compared with other balance systems) and fastened to an engine block or other suitable stationary object, thus saving volume that would be dedicated to the rotating shaft. The torque distribution is embedded with the in-line balance shaft system. Therefore, no torque distribution mechanism, such as a belt, chain and/or tensioner, is needed.
In certain embodiments, the internal combustion engine includes a crankshaft including an outer crankshaft gear and an in-line balance shaft system coupled to the crankshaft. The in-line balance shaft system is configured to provide concurrent and counter-rotating balance forces to balance reciprocating inertial forces of the internal combustion engine. The in-line balance shaft system includes a planetary gear set coupled to the crankshaft. The planetary gear set is coupled to the outer crankshaft gear such that rotation of the crankshaft drives the planetary gear set. The planetary gear set includes an input gear and an output gear. The input gear is coupled to the crankshaft such that rotation of the crankshaft causes rotation of the input gear. The planetary gear set is configured to provide a 1:1 gear ratio between the input gear and the output gear such that the input gear and the output gear rotate at a same speed upon rotation of the crankshaft. The in-line balance shaft system includes a gear counterweight coupled to the output gear. The gear counterweight is configured to balance the crankshaft upon rotation of the crankshaft. The in-line balance shaft system includes a balance shaft gear, and the outer crankshaft gear is meshed with the balance shaft gear such that rotation of the crankshaft causes rotation of the balance shaft gear. The in-line balance shaft system includes a balance shaft coupled to the balance shaft gear such that the balance shaft rotates in unison with the balance shaft gear. The crankshaft includes a plurality of crankshaft counterweights. The crankshaft gear is coupled to at least one of the plurality of crankshaft counterweights such that the crankshaft gear rotates in unison with the plurality of crankshaft counterweights. The crankshaft rotates about a crankshaft axis.
The balance shaft rotates about a balancer axis. The crankshaft axis is offset from the balancer axis. The balancer axis is parallel to the crankshaft axis. The outer crankshaft gear is configured to rotate about the crankshaft axis. The balance shaft gear is configured to rotate about the balancer axis. The in-line balance shaft system further includes a shaft counterweight directly coupled to the balance shaft gear such that rotation of the balance shaft gear causes rotation of the shaft counterweight. The gear counterweight is directly coupled to the output gear. The input gear is a sun gear, the balance shaft is directly coupled to the sun gear such that rotation of the balance shaft causes rotation of the sun gear, and the sun gear is configured to rotate about the second rotational axis. The planetary gear set includes a first planet gear meshed with the sun gear such that rotation of the sun gear causes the first planet gear to orbit around the sun gear. The planetary gear set includes a planet carrier coupled to the first planet gear, the internal combustion engine includes an engine block. The planet carrier is coupled to the engine block such that the planet carrier remains stationary upon rotation of the sun gear and the first planet gear. The planetary gear set includes a second planet gear coupled to the first planet gear such that the first planet gear and the second planet gear rotate in unison. The output gear is a ring gear. The ring gear is meshed with the second planet gear such that rotation of the second planet gear causes rotation of the ring gear, thereby causing the sun gear and the ring gear to rotate in opposite directions. The gear counterweight is directly coupled to the ring gear to provide a counter-rotating balance force, and the ring gear is configured to rotate about the second rotational axis. The internal combustion engine is a 4-cylinder engine.
In certain embodiments, the internal combustion engine includes a crankshaft defining a crankshaft axis and including a first end portion and a second end portion opposite the first end portion. The second end portion is spaced apart from the first end portion along the crankshaft axis. The crankshaft is configured to rotate about the crankshaft axis. The internal combustion engine further includes an in-line balance shaft system coupled to the crankshaft. The in-line balance shaft system is configured to provide concurrent and counter-rotating balance forces to balance reciprocating inertial forces of the internal combustion engine. The in-line balance shaft system includes a first planetary gear set coupled to the first end portion of the crankshaft and a second planetary gear set coupled to the second end portion of the crankshaft such that the first planetary gear set and the second planetary gear set are spaced apart from each other along the crankshaft axis. Each of the first planetary gear set and the second planetary gear set includes an input gear and an output gear. The input gear is coupled to the crankshaft such that rotation of the crankshaft causes rotation of the input gear. Each of the first planetary gear set and the second planetary gear set is configured to provide a 1:1 gear ratio between the input gear and the output gear such that the input gear and the output gear rotate at a same speed upon rotation of the crankshaft. The in-line balance shaft system includes a gear counterweight coupled to the output gear, wherein the counterweight is configured to balance the crankshaft upon rotation of the crankshaft. The input gear is a sun gear, and the crankshaft is directly coupled to the sun gear such that rotation of the crankshaft causes rotation of the sun gear. Each of the first planetary gear set and the second planetary gear set includes a respective first planet gear meshed with the sun gear such that rotation of the sun gear causes the first planet gear to orbit around the sun gear.
The sun gear of each of the first planetary gear set and the second planetary gear set is configured to rotate about the crankshaft axis. The crankshaft includes a forwardmost end and a rearmost end opposite the forwardmost end, the first end portion includes the forwardmost end of the crankshaft. The second end portion includes the rearmost end of the crankshaft. The first planetary gear set is closer to the forwardmost end than to the rearmost end of the crankshaft. The second planetary gear set is closer to the rearmost end than to the forwardmost end of the crankshaft. The internal combustion engine is a 3-cylinder engine. Each of the first planetary gear set and the second planetary gear includes a planet carrier coupled to the first planet gear. The internal combustion engine includes an engine block. The planet carrier is coupled to the engine block such that the planet carrier remains stationary upon rotation of the sun gear and the first planet gear. Each of the first planetary gear set and the second planetary gear set includes a respective second planet gear coupled to the first planet gear such that the first planet gear and the second planet gear rotate in unison. The output gear is a ring gear. The ring gear is meshed with the second planet gear such that rotation of the second planet gear causes rotation of the ring gear, thereby causing the sun gear and the ring gear to rotate in opposite directions. The gear counterweight is directly coupled to the ring gear to provide a counter-rotating balance force.
In certain embodiments, the in-line balance shaft system is configured to be coupled to a crankshaft of an internal combustion engine and includes a planetary gear set coupled to the crankshaft. The planetary gear set includes a sun gear. The sun gear is coupled to the crankshaft such that rotation of the crankshaft causes rotation of the sun gear. The planetary gear set includes a ring gear. The planetary gear set is configured to provide a 1:1 gear ratio between the sun gear and the ring gear such that the sun gear and the ring gear rotate at a same speed upon rotation of the crankshaft. The in-line balance shaft system includes a gear counterweight coupled to the ring gear. The planetary gear set includes a first planet gear meshed with the sun gear such that rotation of the sun gear causes the first planet gear to orbit around the sun gear. The planetary gear set includes a second planet gear coupled to the first planet gear such that the first planet gear and the second planet gear rotate in unison. The ring gear is meshed with the second planet gear such that rotation of the second planet gear causes rotation of the ring gear, thereby causing the sun gear and the ring gear to rotate in opposite directions. The in-line balance shaft system includes a balance shaft gear configured to mesh with an outer crankshaft gear of the crankshaft such that rotation of the crankshaft causes rotation of the balance shaft gear. The in-line balance shaft system includes a balance shaft coupled to the balance shaft gear such that the balance shaft rotates in unison with the balance shaft gear. The in-line balance shaft system includes a shaft counterweight directly coupled to the balance shaft gear such that rotation of the balance shaft gear causes rotation of the shaft counterweight. The first counterweight mass is directly coupled to the ring gear to provide a counter-rotating balance force. The balance shaft is directly coupled to the sun gear such that rotation of the balance shaft causes rotation of the sun gear. The first counterweight mass is configured to balance the crankshaft upon rotation of the crankshaft. The planetary gear set includes a planet carrier coupled to the first planet gear. The planet carrier is configured to remain stationary upon rotation of the sun gear and the first planet gear. The in-line balance shaft system is configured to balance reciprocating inertial forces of the internal combustion engine. The in-line balance shaft system is configured to provide concurrent and counter-rotating balance forces.
The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes for carrying out the disclosure when taken in connection with the accompanying drawings.
With reference to
The crankshaft 14 is elongated along a crankshaft axis C and is configured to rotate about the crankshaft axis C. In the depicted embodiment, the crankshaft 14 includes a plurality of crankshaft counterweights 18, a plurality of crank arms 20, a plurality of main bearing journals 22, a plurality of crank pins 24, and a flywheel mounting flange 26. Each crank pin 24 interconnects two of the crank arms 20. The internal combustion engine 10 further includes a plurality of connecting rods 25 (
The internal combustion engine 10 further includes an in-line balance shaft system 30 mechanically coupled to the crankshaft 14. In particular, the in-line balance shaft system 30 is mechanically coupled to the outer crankshaft gear 27. As such, torque is transmitted from the outer crankshaft gear 27 to the in-line balance shaft system 30. Therefore, rotation of the crankshaft 14 drives the in-line balance shaft system 30. The in-line balance shaft system 30 is configured to balance reciprocating inertial forces of the internal combustion engine 10. Moreover, the in-line balance shaft system 30 is configured to provide concurrent and counter-rotating balance forces. In the depicted embodiment, the in-line balance shaft system 30 may be entirely disposed within the oil pan 28.
With specific reference to
The planetary gear set 32 includes an input gear 44 (which may be a sun gear 46) directly coupled to the balance shaft 36. As such, rotation of the balance shaft 36 causes rotation of the input gear 44 (e.g., sun gear 46) about the balancer axis B. In particular, the input gear 44 is press-fit or locked to the balance shaft 36. The balance shaft 36 and the input gear 44 are configured to rotate in unison. Generally, the input gear 44 is coupled to the crankshaft 14. As such, rotation of the crankshaft 14 causes rotation of the input gear 44. The planetary gear set 32 further includes a planet carrier 48 coupled to the balance shaft 36. The second roller bearing 42 is disposed between the planet carrier 48 and the balance shaft 36 to allow rotation of the balance shaft 36 relative to the planet carrier 48. The planet carrier 48 is coupled to the engine block 12. As such, the planet carrier 48 remains stationary upon rotation of the input gear 44 (e.g., sun gear 46). For instance, the planet carrier 48 may be fastened to the engine block 12 to provide load support. The planetary gear set 32 further includes a first planet gear 50 meshed with the input gear 44 (e.g., sun gear 46). As such, rotation of the input gear 44 (e.g., sun gear 46) causes the first planet gear 50 to orbit around the input gear 44 (e.g., sun gear 46). The input gear 44 (e.g., sun gear 46) has a number of input teeth 47. The first planet gear 50 is configured to orbit around the balancer axis B. The planetary gear set 32 includes a second planet gear 52 coupled to the first planet gear 50. As such, the first planet gear 50 and the second planet gear 52 rotate in unison. The second planet gear 52 is configured to orbit around the balancer axis B. In the depicted embodiment, a fastener 54 (e.g., a bolt) extends through the planet carrier 48 and directly couples the first planet gear 50 to the second planet gear 52. The first planet gear 50 has a number of first teeth 51, and the second planet gear 52 has a number of second teeth 53.
The planetary gear set 32 further includes an outer gear 56, such as a ring gear 58. The ring gear 58 is meshed with the second planet gear 52, thereby allowing the planetary gear set 32 to provide a 1:1 gear ratio between the input gear 44 (e.g., sun gear 46) and the output gear 56 (e.g., ring gear 58). As such, the input gear 44 and the output gear 56 rotate at a same speed upon rotation of the crankshaft 14. However, the input gear 44 and the outer gear 56 rotate in opposite directions upon rotation of the crankshaft 14. Both the input gear 44 (e.g, sun gear 46) and the output gear 56 (e.g., ring gear 58) are configured to rotate about the balancer axis B. The ring gear 58 defines an outer ring surface 60 and an inner ring surface 62 opposite the outer ring surface 60. The planetary gear set 32 includes a gear counterweight 64 directly coupled to the outer ring surface 60 of the ring gear 58. Accordingly, the gear counterweight 64 is configured to balance the crankshaft upon rotation of the crankshaft 14 by providing a counter rotating balancing force. The gear counterweight 64 may be fastened or welded to the outer ring surface 60 of the ring gear 58. Therefore, the gear counterweight 64 rotates in unison with the ring gear 58. It is contemplated that the gear counterweight 64 may be an integral part of the ring gear 58. In the depicted embodiment, the gear counterweight 64 may be configured as a curved plate. Because the gear counterweight 64 is disposed on the outer ring surface 60 of the ring gear 58, it is considered an eccentric mass in relation to the balancer axis B. The outer gear 56 (e.g., ring gear 58) has a number of gear teeth 59 extending from the inner ring surface 62 toward the balancer axis B. The gear counterweight 64 has a mass MC2. To properly balance the internal combustion engine 10, the relationship between the gear counterweight 64 and the shaft counterweight 38 is characterized by the following equation:
M
C1
·R
COG1
=M
C2
·R
COG2
where:
MC1 is the mass of the shaft counterweight 38;
MC2 is the mass of the gear counterweight 64;
RCOG1 is a center of gravity radius of the shaft counterweight 38 that is measured from the balancer axis B to the center of gravity of the shaft counterweight 38; and
RCOG2 is a center of gravity radius of the gear counterweight 64 that is measured from the balancer axis B to the center of gravity of the gear counterweight 64.
To properly balance the internal combustion engine 10, the relationship among the outer gear 56 (e.g., the ring gear 58), the input gear 44 (e.g., the sun gear 46), the first planet gear 50, and the second planet gear 52 is characterized by the following equation:
where:
N1 is the number of input teeth 47 of the input gear 44 (e.g., sun gear 46);
N2 is the number of first teeth 51 of the first planet gear 50;
N3 is the number of second teeth 53 of the second planet gear 52; and
N4 is the number of gear teeth 59 of the output gear 56 (e.g., ring gear 58).
With reference to
With reference to
While the best modes for carrying out the disclosure have been described in detail, those familiar with the art to which this disclosure relates will recognize various alternative designs and embodiments for practicing the disclosure within the scope of the appended claims.