The present invention relates generally to the field of engines. More specifically, the invention relates to an engine that is integrated with a hydraulic pump and a pressure washer having an integrated engine and hydraulic pump.
To provide pressurized water, some current pressure washers use internal combustion engines coupled to axial piston pumps. Energy typically flows from an internal combustion engine to the chamber of a water pump piston in the following order: combustion occurs in the engine, creating pressure through expansion of heated gases; the pressure is converted to linear motion via a piston; linear motion is converted to rotary motion via a connecting rod and crankshaft; rotary motion is converted back to linear motion via a wobble plate; and linear motion is converted to a pressure via water pump pistons. Energy losses occur in each of these steps. Furthermore, the large number of components may cause these engines, as well as the pressure washers into which they are incorporated, to be expensive, complex, and heavy.
One embodiment of the invention relates to an engine including a piston located in a piston bore within a cylinder block, a first spring biasing the piston in a first direction, and a second spring biasing the piston in a second direction opposite the first direction, wherein the first spring and the second spring control a displacement of the piston.
Another embodiment of the invention relates to an engine including a piston assembly including an engine piston and a hydraulic pump piston rigidly connected to the engine piston, wherein the hydraulic pump piston is located within a hydraulic pump chamber, a force converter configured to absorb a first force applied to the piston assembly and to apply a second force to the piston assembly in a direction opposite to the first force, and a pressurized fluid outlet from the hydraulic pump chamber, wherein reciprocation of the piston assembly causes fluid to exit the hydraulic pump chamber through the pressurized fluid outlet.
Another embodiment of the invention relates to a pressure washer including an engine including a piston assembly including an engine piston and a hydraulic pump piston rigidly connected to the engine piston, wherein the hydraulic pump piston is located within a hydraulic pump chamber, a water inlet fluidly connected to a hydraulic pump chamber, a pressurized water outlet from the hydraulic pump chamber, and a spray gun fluidly coupled to the pressurized water outlet, wherein reciprocation of the piston assembly causes fluid to flow from the hydraulic pump chamber through the pressurized fluid outlet to the spray gun.
Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, in which:
Certain embodiments of the invention reduce cost by eliminating components from the engines typically used in pressure washers. The disclosed engines are intended to increase the efficiency of energy transfer, which improves engine performance. Furthermore, the disclosed engines are intended to have a reduced weight compared to conventional engines. In turn, the pressure washers or other machines into which the engines are incorporated are intended to be lighter and more manageable. It should be understood that the engine embodiments disclosed herein may be used in any type of equipment requiring an engine, and in particular in any type of equipment requiring both an engine and a pump. Although it is preferable for the engines to be integrated with a liquid pump, engines integrated with other types of pumps fall within the scope of this application.
Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details set forth in the description or illustrated in the figures. It should also be understood that the terminology is for purpose of description only and should not be regarded as limiting.
In the two-stroke engine 112 shown in
Fluid or water enters the engine 112 and cylinder block 132 through a fluid inlet 154. The fluid may flow through a water jacket 150 in order to facilitate cooling of the engine 112. The water jacket 150 is formed within the cylinder block 132, particularly in the region of the engine piston bore 144. Water within the water jacket 150 cools the engine by absorbing heat created by combustion within the combustion chamber 142. The water jacket 150 can be formed in a variety of configurations within the cylinder block 132 and/or engine housing to most effectively cool the engine 112. A pipe 152 connects portions of the water jacket 150 and fluidly connects the fluid inlet 154 to the hydraulic pump chamber 148. Other structures may also be employed to route fluid from the fluid inlet 154 to the hydraulic pump chamber 148. For example, a pathway can be formed within the cylinder block 132.
Fluid enters the hydraulic pump chamber 148 through first check valve 156. Once within the hydraulic pump chamber 148, fluid exits through second check valve 158. Other suitable types of valves and mechanisms may also be employed to control the flow of fluid into and out of the hydraulic pump chamber 148. Fluid flowing out of the second check valve 158 is pressurized due to the reciprocation of the piston assembly 180 (described below), and flows out of the engine through a pressurized fluid outlet 122. The pressurized fluid may then be routed to an external water sprayer 120 of a pressure washer (see
An engine piston 160 is located within the engine piston bore 144. The engine piston 160 may comprise an engine piston head 162, ring grooves 164, and a skirt 166. The engine piston 160 reciprocates within the engine piston bore 144 from a top dead center position to a bottom dead center position.
In an exemplary embodiment, a rod 168 connects the engine piston 160 to a base 170. The rod 168 may be of any shape and size, and can be made of any material suitable for withstanding the forces exerted onto the engine piston 160. The base 170 comprises a magnet 172, which will be discussed below in conjunction with the ignition system.
A hydraulic pump piston 174 is connected to the base 170.
In some embodiments, the engine piston 160 and hydraulic pump piston 174 are rigidly connected to form an integrated piston assembly 180 that reciprocates within the cylinder block 132. In some embodiments, the engine piston 160 and the hydraulic pump piston 174 are axially aligned with each other (i.e., the longitudinal axis of the engine piston 160 and the longitudinal axis of the hydraulic pump piston 174 are collinear so that the engine piston 160 and the hydraulic pump piston 174 reciprocate along the same axis). In an exemplary embodiment, the piston assembly 180 reciprocates without the aid of a crankshaft. Thus, the engine 112 is a free-piston engine. In general terms, “free-piston” indicates that the motion of a piston is not restricted by the motion of a rotating crankshaft, which converts linear (reciprocating) motion of a piston into rotary motion. The engine 112 therefore does not convert the linear motion of the engine piston 160 to rotary motion. Instead, the engine piston 160 and the hydraulic pump piston 174 reciprocate as a unit within the cylinder block 132. The engine 112 comprising an integrated engine piston 160 and hydraulic pump piston 174 is referred to as a free-piston engine pump (FPEP).
A force converter, shown as, but not limited to, a spring 184 is provided to control displacement and reciprocation of the piston assembly 180. The force converter may be any structural mechanism capable of absorbing, storing, and applying forces to a component of the piston assembly 180. In the illustrated embodiment, the force converter comprises at least one spring 184. The spring 184 is disposed between the engine piston 160 and the divider 140. However, the spring 184 may be positioned in any location that will allow it to control displacement of the piston assembly 180. For example, one end of the spring 184 could be connected to the circumference of the engine piston bore 144 or to another surface of the cylinder block 132 instead of to the divider 140. Furthermore, the spring 184 may be disposed entirely on one side of the rod 168, instead of wrapping around the rod 168. In some embodiments, the spring 184 may not be fixed to one or both of the engine piston 160 and the divider 140, but rather only abut the surface of the adjacent structure. Spring 184 may further comprise multiple spring elements.
The spring 184 controls displacement of the assembly by absorbing a force applied to the engine piston 160 by, for example, the ignition of an air-fuel mixture within the combustion chamber 142. During the combustion stroke, the ignition of the air-fuel mixture in the combustion chamber 142 urges the engine piston 160 towards a bottom dead center position (to the right in
In some embodiments, the force converter further comprises a second spring 186. The second spring 186 is disposed between the divider 140 and the base 170. As the spring 184 (referred to hereinafter as the “first” spring 184) is compressed during the combustion stroke of the piston assembly 180, the second spring 186 expands. In contrast, when the first spring 184 expands during the compression stroke of the piston assembly 180, the second spring 186 is compressed. As described above in relation to the first spring 184, the second spring 186 may also be located in any suitable location, may be fixed or unfixed to its adjacent structures, and may comprise multiple spring elements.
The properties (e.g. material, fatigue strength, size, etc.) of the two springs 184, 186 are selected to effectively control displacement of the piston assembly 180 during operation of the engine 112. The selection of the two springs 184, 186 should take into consideration various additional factors related to the engine 112, including, for example, the sizes of the engine piston 160 and hydraulic pump piston 174, the forces exerted by combustion within the combustion chamber 142, and the pressure of fluid within the hydraulic pump chamber 148. When the engine 112 is turned off, the piston assembly 180 should remain in an intermediate position. That is, the forces exerted by the springs 184, 186 should hold the piston assembly 180 in a position that is between top dead center and bottom dead center (see
An ignition system for the engine 112 may include an ignition coil 188 and one or more spark plugs 190. A magnet 172 located on the base 170 generates timed sparks from the spark plugs 190, which extend through a cylinder head into the combustion chamber 142. The magnet 172 may be located on any component of the piston assembly 180. Furthermore, any suitable type of ignition system may be employed to ignite fuel in the combustion chamber 142. Wiring and tubing connect the spark plug 190 and the combustion chamber 142 to a primer source and additional components of the ignition system.
In the embodiment of
The engine 112 shown in
The second piston 196 is located in a second piston bore 204 and is configured to reciprocate within the second piston bore 204 in connection with reciprocation of piston assembly 180. The second piston bore 204 includes a hydraulic pump oil seal 176 and a hydraulic pump fluid seal 178 to prevent leakage of oil and fluid, respectively. The second piston 196 helps control the movement of piston assembly 180 by vibration cancellation. The hydraulic pump chamber 206 of the second piston 196 includes check valves 208 and 210. The check valves may fluidly connect the hydraulic pump chamber 206 of the second piston 196 to a water jacket system (not shown in
To begin reciprocation of a piston assembly 180 in any of the embodiments described above, the engine 112 may include an additional structure geared towards initiating motion. For example, a hand pump may be linked to the hydraulic pump chamber 148, 206 of the hydraulic pump piston 174 or the second piston 196. A user operates the hand pump to apply pressure to the hydraulic pump chamber 148 or 206 and initiate movement of the piston assembly 180 and/or the second piston 196. Alternatively, a pump may be provided to pump air into the combustion chamber 142. Fuel can then be injected into the combustion chamber 142 and ignited, exerting a force onto the engine piston head 162.
Fluid enters the hydraulic pump chamber of the first hydraulic piston 234 through a first check valve 248 and exits through a second check valve 250. Fluid enters the hydraulic pump chamber of the second hydraulic piston 236 through a third check valve 252 and exits through a control valve 254 and a fourth check valve 256. The control valve 254 opens and closes in response to the back pressure upstream of the valve 246 in the spray gun 244. At a first relatively high back pressure with the valve 246 closed, the control valve 254 closes. At a second relatively low back pressure with the valve 246 open, the control valve 254 opens. If the valve 246 in the spray gun 244 is open, the fluid passes through the spray gun 244 and is output through the spray gun nozzle. If the valve 246 is closed, the back pressure upstream from the valve 246 increases, closing the control valve 254. With the control valve 254 closed, the outlet passage from the hydraulic pump chamber of the second hydraulic piston 236 is closed. The outlet passage from the hydraulic pump chamber of the first hydraulic piston 234 remains open and fluid is received in the accumulator 260. The second hydraulic piston 236 is stopped in a retracted position (top dead center) while the first hydraulic piston 234 is stopped in an extended position (bottom dead center) (as shown in
The construction and arrangement of the engines and pressure washer, as shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, 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 described herein. Some 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. 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 invention.