The field is reduction of noise, vibration, and harshness (NVH) in an internal combustion engine. More specifically, the field encompasses reduction of gear noise and vibration in the gear train of an opposed-piston engine through a combination of gear lash control and reduction of torsional vibrations of the crankshafts in the engine.
Gear vibrations in an internal combustion engine can lead to intense whining, sharp impulse noise (e.g., rattle), or both. These noises can cause extreme operator and passenger discomfort in a vehicle. Engine whine and rattle also add to the constant cacophony that can make proximity to transportation routes unpleasant. Because of this, performance standards and environmental regulations relating to vehicles increasingly include NVH limits.
Backlash is a gap (e.g., lash) typically present in meshing gears to account for manufacturing tolerances, to prevent binding of gears at higher operating temperatures, and to account for other variations in gears that can exist during operation of an engine. In gear trains of opposed-piston engines, during torque reversals, the driving gear moves into contact with both flanks of the corresponding driven gear in a mesh, thereby producing gear rattle, especially when there is excessive backlash in the system.
The gear train of an opposed-piston engine with dual crankshafts inherently experiences events where contact is lost between teeth of adjacent gears in a mesh that produces rattle and vibration. For example, in the case where a phase difference is provided between the crankshafts (i.e., crank lead) in order to differentiate port opening and closing times, the gear train is subjected to a torque reversal event at least once every cycle of engine operation. Torque reversals result in gear train rattle when gear backlash is present.
Backlash control in an opposed-piston engine can involve a balance between noise control, minimization of friction loss, and efficient transfer of torque in the gear train. Conventional backlash controls include methods and apparatus that fix the backlash of an engine prior to operation of the engine (e.g., movement of idler gears, the use of select fit gears), or perhaps additionally after operation and alteration of an engine. Scissor gears of the conventional type, such as described in U.S. Pat. No. 5,979,259, are pre-tensioned with one or more torsional springs to take up the lash in a gear mesh between the scissor gear and an adjacent gear. Fluctuations in crankshaft torsional velocity of an opposed-piston engine can be mitigated, that is lessened or eliminated, by the use of a viscous damper, a centrifugal pendulum absorber, or a combination thereof. In an engine, minimization of noise, vibration, and harshness, backlash mitigation can be combined with crankshaft torsional velocity fluctuation reducing means.
A system and method for dynamic control of noise, vibration, and harshness in an opposed-piston engine with one or more crankshafts are provided in the embodiments described below. The noise, vibration, and losses caused by backlash and/or fluctuations in the crankshaft torsional velocity during operation of the engine can be mitigated by combining at least two of a backlash reducing device (e.g., a scissor gear or other anti-backlash device), a centrifugal pendulum absorber, and a viscous damper.
Some implementations are directed to an opposed-piston internal combustion engine that includes a gear train with an arrangement of gears coupling at least one crankshaft to an output drive and two or more of a backlash reducing gear in the gear train, a centrifugal pendulum absorber on the at least one crankshaft, and a viscous damper on the at least one crankshaft.
In a related aspect, some implementations provide an opposed-piston internal combustion engine that includes a gear train with an arrangement of gears coupling at least one crankshaft to an output drive and a means for reducing backlash and/or a means for crankshaft torsional velocity fluctuation mitigation.
The following features can be present in the opposed-piston internal combustion engine in any suitable combination. The means for crankshaft torsional velocity fluctuation mitigation can include a viscous damper, a centrifugal pendulum absorber, or any equivalent. In some implementations, the means for crankshaft torsional velocity fluctuation mitigation can include both a viscous damper and a centrifugal pendulum absorber. The engine can include a first and a second crankshaft, in which the gear train includes a first crank gear attached to the first crankshaft and a second crank gear attached to the second crankshaft, at least one idler gear, and a power take-off gear. The means for reducing backlash can include a positioning mechanism, a scissor gear, or any equivalent thereof. In some aspects, the scissor gear can have two or three gears in a gear assembly. In such aspects, the scissor gear can include any of a biasing spring, a roller clutch, and a hydraulic biasing means. Alternatively, or additionally, the backlash reducing means can include the at least one idler gear.
In a further related aspect, a method of reducing noise, vibration, and harshness in an opposed-piston engine is provided in some implementations. The method can include reducing rattle in a gear train using a backlash reducing means and damping crankshaft torsional velocity fluctuation during operation of the opposed-piston internal combustion engine. In some implementations, the method can include engaging the backlash reducing means upon start-up of the opposed-piston internal combustion engine.
A specialized gear, system, and method for dynamic control of backlash in an opposed-piston engine are described. Using a backlash reducing gear, the amount of backlash between at least two adjacent gears in a gear train can be reduced, and at the same time noise and rattling resulting from loss of contact between the teeth of adjacent gears (due to, e.g., systemic torque reversals) can be damped during operation of the engine. While the engine is operating, adjustments to the backlash between at least two adjacent gears can be continuous and in response to changes in the engine such as temperature or wear.
As per
The engine 10 can combine the viscous dampers 240 and centrifugal pendulum absorbers 250 to reduce or mitigate any fluctuations in the crankshaft speed (i.e., torsional velocity) when the engine 10 is operating. Additionally, the engine 10 may include a means for reducing backlash, or anti-backlash means, in the gear train 30, like a scissor gear backlash reducing means or a gear positioning backlash reducing mechanism.
Though the opposed-piston engine 10 shown in
When the engine is in use, the motion of each mass 455 about the rollers 456 act in conjunction with the motion of the other masses 455 to reduce the amplitude of torsional vibrations. In some implementations, a centrifugal pendulum absorber 400 can be configured to reduce the amplitude of an entire order of vibrations. Further, a centrifugal pendulum absorber can be designed to be effective at an order corresponding to a dominant firing order in the engine. Alternatively, in the case of an opposed-piston engine with two crankshafts and a phase difference between exhaust pistons and intake pistons (e.g., crank lead) a centrifugal pendulum absorber can be designed to be effective at two or more dominant orders including the firing order, n, and an additional order, 2n. As is known in the art, a centrifugal pendulum absorber can be tailored to address various orders of vibration by having different pendulum inertia and paths (e.g., circular, cycloidal, epicycloidal, or tautochronic paths) for each order.
In some implementations, when an opposed-piston engine has more than one crankshaft (e.g., two crankshafts) the torques and vibrational modes experienced during engine operation can differ at each crankshaft. In such engines, a combination of a damping means (e.g., a viscous damper) and an absorber means (i.e., a centrifugal pendulum absorber) can be used for each crankshaft. Alternatively, some crankshafts can use a combination of a damping means and an absorber means, while one or more other crankshafts in the opposed-piston engine can use multiple damping means or multiple absorber means to mitigate torsional vibrations.
In use, a gear train of an engine can have a backlash reducing means. The backlash reducing means can include at least one backlash reducing gear adjacent to a mating gear. The backlash reducing gear can be any of a crank gear, idler gear, or drive gear. Other types of backlash reducing means, besides a backlash reducing gear, can include measures to adjust positions of gears relative to each other (e.g., a positioning mechanism) or adjust tensioning, finding a balance between increased friction and reduced center-to-center distance between adjacent gears. Some backlash reducing means can engage when the opposed-piston engine starts up. Alternatively, the backlash reducing means can be selectively engaged or always engaged.
A backlash reducing gear can have a first and a second gear which have approximately the same diameter and teeth on each gear in a gear assembly. The first and second gears of the backlash reducing gear can move relative each to other so that the width of the effective gear tooth made by the first and second gear increases or decreases, as needed. The teeth of an adjacent mating gear exert a reaction force on the teeth of the first and second gear of the backlash reducing gear. That reaction force is countered by the biasing mechanism within the backlash reducing gear (e.g., biasing spring, hydraulic biasing means).
One type of backlash reducing gear is a scissor gear. A scissor gear can have two or more gears, each with teeth. In a scissor gear, each gear is tensioned to a default position with respect to each other using any of a snap ring, multiple biasing springs, and hydraulically biased scissor gears. When the backlash reducing gear is in a first, biased position, the effective tooth thickness (e.g., width of a gear tooth) can be equivalent to that of a tooth with a width from each of the first gear and the second gear.
In use, the scissor gear is placed next to a mating gear. The teeth of the mating gear can be sufficiently close together (e.g., have a sufficient circular pitch), so that the first and second gears of the scissor gear will need to be rotated to allow for a meshing of the gear teeth. During engine operation, as the spacing of the teeth of the mating gear reduces (e.g., the tooth width of the mating gear expand), the effective width of the teeth of the scissor gear will reduce, so that the outside of the teeth of the first and second gears move closer together. The first and second gears of the scissor gear will remain tensioned so that the effective tooth thickness maintains close contact with the mating gear. In this way, the scissor gear prevents lash from forming between itself and the mating gear.
However, the location of the backlash reducing gears in the idler gear positions 660 in the gear train 630 allows each backlash reducing gear to adapt only to the smallest amount of backlash in each gear mesh. For example, an idler gear with a primary gear and a secondary gear in the gear assembly will yield an effective tooth width that accommodates either the adjacent power take-off gear 661 or the adjacent crank gear 662 or 663. In some implementations, a backlash reducing gear can include a gear assembly with three gears, a first, second, and third gear. Such a backlash reducing gear can accommodate two adjacent gears with fixed teeth spacing or fixed center distance. A gear that can accommodate two adjacent gears is described in greater detail in U.S. Pat. No. 9,958,057, “Gear Backlash Control for an Opposed-Piston Engine,” issued May 1, 2018, or U.S. Pre-Grant publication US 2004/0089089 (published May 13, 2004 by Stevens et al.).
In an opposed-piston engine, a backlash reducing means (e.g., one or more backlash reducing gears, a positioning mechanism) can be used with a means for mitigating crankshaft torsional velocity fluctuations or torsional vibration (e.g., a viscous damper, a centrifugal pendulum absorber). The backlash reducing means can be used in the engine gear train, while the crankshaft torsional velocity fluctuation mitigating means can be applied to one or more crankshafts, typically at the end of a crankshaft. If more than one crankshaft is present in the engine, each crankshaft can have crankshaft torsional velocity fluctuation mitigating means attached to it which address the specific modes of vibration and velocity fluctuation for that crankshaft.
A gear train, like the one shown in
A gear train of two or more gears (e.g., n gears) can have one or more backlash reducing gears, as described above. For example, a gear train of n gears, one gear can be a backlash reducing gear, n-1 gears can be backlash reducing gears, n-2 gears can be backlash reducing gears, up to n gears (i.e., all the gears in the train) can be backlash reducing gears. The backlash reducing gears in a gear train can be all gears of a first and second gear or all backlash reducing gears can be gears with a first, second, and third gear, Alternatively, the backlash reducing gears in a gear train can be a combination of gears of a first and second gear and gears of a first, second, and third gear. Backlash reducing gears with a first, second, and third gear can accommodate two adjacent gears with different fixed gear teeth spacing. In some implementations, in a gear train, a single gear post can attach to two or more gears, such as at least one backlash reducing gear and one conventional gear, or to two or more backlash reducing gears. A gear post attached to two or more gears can allow the gear train to accommodate gears of multiple sizes (e.g., gears of multiple diameters).
In the gear train of an engine, a backlash reducing gear as described herein can be placed adjacent to at least one other gear. The gear train can have three or more gears. For each pair of adjacent gears, at least one gear can be a backlash reducing gear to minimize backlash and allow the engine to better accommodate systematic torque reversals, reducing engine rattle.
The scope of patent protection afforded the novel tools and methods described and illustrated herein may suitably comprise, consist of, or consist essentially of the elements including an opposed-piston engine with at least two of a gear train with a backlash reducing means, a viscous damper, and a centrifugal pendulum absorber that allow for the reduction or elimination of noise, vibration, and/or harshness in the engine. Further, the novel tools and methods disclosed and illustrated herein may suitably be practiced in the absence of any element or step which is not specifically disclosed in the specification, illustrated in the drawings, and/or exemplified in the embodiments of this application. Moreover, although the invention has been described with reference to the presently preferred embodiment, it should be understood that various modifications can be made without departing from the spirit of the invention. Accordingly, the invention is limited only by the following claims.
This Application is a continuation of PCT application PCT/US2018/035605, filed Jun. 1, 2018, which claims priority to U.S. provisional application for patent U.S. 62/514,366, filed Jun. 2, 2017. This application contains subject matter related to the subject matter of the following pending U.S. patent applications: U.S. application Ser. No. 15/176,818, filed 8 Jun. 2016, now U.S. Pat. No. 9,958,057; U.S. application Ser. No. 131385,539, filed Feb. 23, 2012 and published as U.S. 2012/0285422; U.S. application Ser. No. 13/858,943, filed Apr. 8, 2013, and published as U.S. 2014/0299109; U.S. application Ser. No. 13/944,787, filed Jul. 17, 2013, now U.S. Pat. No. 9,618,108: U.S. application Ser. No. 14/074,618, filed Nov. 7, 2013, and published as US 2015/0020629; U.S. application Ser. No. 14/450,747, filed Aug. 4, 2014, now U.S. Pat. No. 9,772,030; and U.S. application Ser. No. 15/142,261, filed Apr. 29, 2016, and published as U.S. 2017/0314646.
Number | Date | Country | |
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62514366 | Jun 2017 | US |
Number | Date | Country | |
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Parent | PCT/US2018/035605 | Jun 2018 | US |
Child | 16669157 | US |