The present disclosure generally relates to internal combustion engines and, more specifically, to pistons for premixed spark-ignited and premixed dual fuel internal combustion engines.
Internal combustion engines include one or more pistons connected to a crankshaft by a connecting rod. During the combustion cycles of the engine, the pistons reciprocate along a longitudinal axis within a combustion chamber defined by the walls of a cylinder to drive the rotation of the crankshaft. For example, in a four stroke combustion cycle of a premixed spark-ignited or dual fuel engine, the piston may move from top dead center to bottom dead center to draw in a mixture of fuel and air into the combustion chamber through the intake valve. Following air/fuel intake, the intake valve closes and the piston moves from bottom dead center to top dead center to compress the air/fuel mixture. Subsequent initiation of combustion of the air/fuel mixture with a flame causes the gases to expand which forces the piston to move from top dead center to bottom dead center. A spark is used to initiate combustion in premixed spark-ignited engines, whereas a small amount of diesel fuel (“pilot” fuel) is ignited by compression to initiate combustion in premixed dual fuel engines. Following combustion, an exhaust valve is then opened, and exhaust gases are evacuated from the combustion chamber as the piston moves from bottom dead center to top dead center, allowing the combustion cycle to repeat.
A piston includes a piston head having an upper surface facing the combustion chamber. Around the periphery of the piston head are a plurality of annular ring grooves that receive piston rings which form a seal between the combustion chamber and the crankcase. In addition, a plurality of “lands” extend between and above the annular ring grooves to confine the piston rings in their respective grooves. Above the top piston ring is a “top land” which extends to the upper surface of the piston head. The piston also includes a skirt that includes a pin bore that receives a wrist pin for connecting the piston to the connecting rod. The wrist pin may serve as a bearing on which the piston rocks from side to side as it reciprocates in the combustion chamber.
In prior art designs, the top land of the piston may have a cylindrical shape with a smaller diameter than the engine cylinder, such that the top land is separated from the cylinder walls by a gap which is accessible to air and fuel in the combustion chamber, but is inaccessible to the propagating flame due to heat loss to the closely-spaced metal surfaces. Moreover, as the piston rocks about the pin bore axis (i.e., in a direction concentric to the pin bore axis), the top land may more closely approach or contact the cylinder wall, temporarily creating blocked crevices containing trapped hydrocarbon fuel that cannot be combusted by the propagating flame. As a result of flame inaccessibility to hydrocarbon fuel trapped in such top land crevices, emissions of unburned or partially unburned hydrocarbons may be undesirably increased, contributing to the greenhouse gas footprint of the machine. Hydrocarbon emissions from top land crevices is a problem associated with premixed spark-ignited and premixed dual fuel engines which, unlike diesel engines that ignite fuel through compression, rely on a propagating flame for combustion.
One approach to reduce hydrocarbon emissions from top land crevices, as described in Canadian Patent Application Number CA 2863036 A1, involves the introduction of an annular chamfered edge around the periphery of the top land to provide a conically-shaped top land. The chamfered area of the top land provides clearance for piston rocking and reduces the crevice volume in the direction of rocking, resulting in reduced unburned/partially burned hydrocarbon emissions. However, while effective, the conical/annular chamfered top land geometry unnecessarily augments the crevice volume near regions of the top land where additional clearance for piston rocking is not needed (i.e., directly above the wrist pin bore). By increasing the crevice volume that is difficult for the combustion flame to access, more unburned or partially burned hydrocarbons may be emitted, counteracting at least some of the emission reductions obtained with the annular chamfered edge.
Thus, there is a need for improved piston top land geometries that help reduce unburned or partially burned hydrocarbon emissions from crevices.
In accordance with one aspect of the present disclosure, a piston for a premixed spark-ignited or a premixed dual fuel internal combustion engine is disclosed. The piston may be configured to reciprocate along a longitudinal axis of a combustion chamber defined by a cylinder of the internal combustion engine. The piston may comprise a piston head that includes an upper surface facing the combustion chamber, and a top annular groove configured to receive a top piston ring. The piston may further comprise a skirt extending from the piston head and including a pin bore extending along a pin bore axis that is configured to receive a wrist pin for connecting the piston to a connecting rod. In addition, the piston may further comprise a top land formed on the piston head that extends between the upper surface and the top annular groove of the piston head. The top land may include an upper annular edge that adjoins the upper surface of the piston head, and a lower annular edge that adjoins the top annular groove. The upper annular edge may have an elliptical shape with a major axis extending parallel to the pin bore axis (when viewed from above the piston head), and a minor axis extending perpendicular to the pin bore axis. The lower annular edge may have a circular shape with a diameter that is substantially equivalent to a length of the major axis of the upper annular edge.
In accordance with another aspect of the present disclosure, a piston for a premixed spark-ignited or a premixed dual fuel internal combustion engine is disclosed. The piston may be configured to reciprocate along a longitudinal axis of a combustion chamber defined by an inner wall of a cylinder of the engine. The piston may comprise a piston head that includes an upper surface facing the combustion chamber, and a top annular groove configured to receive a top piston ring. The piston may further comprise a skirt extending from the piston head and including a pin bore extending along a pin bore axis that is configured to receive a wrist pin for connecting the piston to a connecting rod. The piston may be configured to rock in the cylinder about the pin bore axis. In addition, the piston may further comprise a top land formed on the piston head that extends between the upper surface and the top annular groove of the piston head. The top land may be chamfered in a direction perpendicular to the pin bore axis such that the top land does not contact the inner wall of the cylinder when the piston rocks about the pin bore axis. The top land may be non-chamfered in a direction parallel to the pin bore axis.
In accordance with another aspect of the present disclosure, an internal combustion engine is disclosed. The internal combustion engine may comprise a cylinder having an inner wall defining a combustion chamber, an intake valve configured to permit a mixture of air and fuel to enter the combustion chamber, a combustion initiation device configured to initiate combustion of the mixture of air and fuel in the combustion chamber, and a crankshaft. The internal combustion engine may further comprise a piston connected to the crankshaft through a connecting rod that is configured to reciprocate along a longitudinal axis of the combustion chamber to drive a rotation of the crankshaft. The piston may include a piston head having an upper surface facing the combustion chamber, and a top annular groove receiving a top piston ring. The piston may further include a skirt having a pin bore extending along a pin bore axis that receives a wrist pin that connects the piston to the connecting rod. The piston may be configured to rock within the combustion chamber about the pin bore axis. In addition, the piston may further include a top land formed in the piston head that extends between the upper surface and the top annular groove of the piston head. The top land may include an upper annular edge that adjoins the upper surface of the piston, a lower annular edge that adjoins the top annular groove, and an outer surface extending from the upper annular edge to the lower annular edge. The upper annular edge may have an elliptical shape with a major axis extending parallel to the pin bore axis and a minor axis extending perpendicular to the pin bore axis. The lower annular edge may have a circular shape with a diameter substantially equivalent to a length of the major axis of the upper annular edge such that the outer surface of the top land includes two chamfered surfaces flanking the major axis of the upper annular edge. The two chamfered surfaces may be angled by about 85° to about 89.9° with respect to the upper surface of the piston head.
These and other aspects and features of the present disclosure will be more readily understood when read in conjunction with the accompanying drawings.
Referring now to the drawings, and with specific reference to
In a combustion cycle of the engine 10, an intake valve 24 may be opened and the piston 18 may move down within the cylinder 12 from top dead center to bottom dead center to draw in a “premixed” mixture of air and fuel through an intake manifold 26. The intake valve 24 may then close, and the piston 18 may move up within the cylinder 12 from bottom dead center to top dead center to compress the mixture of air and fuel in the combustion chamber 16. Once compressed, a combustion initiation device 28 may initiate combustion of the air/fuel mixture, and the resulting expansion of the combustion products may force the piston 18 down within the cylinder 12 from top dead center to bottom dead center. If the engine 10 is a premixed spark-ignited engine, the combustion initiation device 28 may be a spark plug. Alternatively, if the engine 10 is a premixed dual fuel engine, the combustion initiation device 28 may be a fuel injector that injects a pilot fuel, such as diesel fuel, that ignites and initiates combustion of a mixture of air and a primary fuel (e.g., natural gas) in the combustion chamber 16. Following combustion, an exhaust valve 30 may open and the piston 18 may move up within the cylinder 12 from bottom dead center to top dead center to push the exhaust gases out of the combustion chamber 16 into an exhaust manifold 32, allowing the combustion cycle to repeat. Although described as a four-stroke engine, it will be understood that the engine 10 may also operate as a two- or six-stroke engine, as will be understood by those with ordinary skill in the art.
With reference to
Referring still to
The two chamfered surfaces 72 may be defined by a chamfer angle θ between the outer surface 68 of the top land 56 and the upper surface 46 of the piston head 36 (see
Turning now to
Thus, the top land 56 may be non-chamfered in a direction parallel to the pin bore axis 42. Unlike conical top land geometries of the prior art which are chamfered around the entire outer surface of the top land, the top land 56 of the piston 18 disclosed herein does not increase the volume of the crevice 70 with chamfered surfaces in the direction that the piston 18 is not rocking. As such, the volume of the crevice 70 is reduced compared with conical top land geometries of the prior art, thus reducing the area that is difficult for the combustion flame to penetrate. Accordingly, even further reductions in hydrocarbon emissions should be achieved with the top land structure disclosed herein compared with conical top land structures of the prior art.
In general, the teachings of the present disclosure may find applicability in many industries including, but not limited to, industries using internal combustion engines that combust a premixed air and fuel charge, such as premixed spark-ignited and dual fuel engines. More specifically, the teachings of the present disclosure may be applicable to any industry aiming to reduce greenhouse gas emissions from premixed spark-ignited or dual fuel engines.
As is known, a piston may rock about the pin bore axis as it reciprocates within the engine cylinder. The top land structure disclosed herein includes chamfered surfaces in a direction perpendicular to the pin bore axis to provide clearance for piston rocking. The chamfered surfaces reduce the crevice volume in the direction of piston rocking compared to cylindrical top land designs of the prior art. The reduced crevice volume reduces the space containing trapped combustion gases that are inaccessible to the flame, resulting in reduced emissions of unburned/partially burned hydrocarbons compared with cylindrical top land designs of the prior art. The chamfered surfaces of the top land disclosed herein are angled such that the chamfered surfaces alternately extend parallel to the inner wall of the cylinder with a minimal space therebetween as the piston rocks. Moreover, compared to conical top land geometries of the prior art which are chamfered around the entire outer surface of the tap land, the top land geometry disclosed herein lacks chamfered surfaces in the direction that the piston is not rocking (directly above the pin bore axis). Thus, the top land geometry of the present disclosure does not expand the crevice volume along portions of the top land that are not in danger of contacting the cylinder inner wall as the piston rocks about the pin bore axis. The reduction in the overall crevice volume compared to conical top land designs of the prior art reduces the space that may contain hydrocarbon fuel molecules that are inaccessible or poorly accessible to the combustion flame. As a result, engine efficiency should be improved, and emissions of unburned/partially burned hydrocarbons as well as the greenhouse gas footprint of the engine should be even further reduced compared to conical top land designs.
It is expected that the technology disclosed herein may find wide industrial applicability in a wide range of areas such as, but not limited to, transportation, construction, agricultural, mining, power generation, drilling, and fracking applications.