This application relies on the priority of provisional application Ser. No. 61183015 filed on Jun. 1, 2009 entitled Variable Stroke Constant Compression Ratio Engine having a common inventor with the present application.
1. Field of the Invention
This invention relates generally to the field of internal combustion engines and more particularly to a multicylinder internal combustion engine having a wobbler connected to the pistons and positionable on a dual angled crank for variation of the stroke while maintaining constant compression ratio.
2. Description of the Related Art
The internal combustion engine in its two current forms (spark ignited gasoline and compression ignition diesel) is poorly suited to efficiently power personal transportation. Automobiles and customer's expectations have evolved such that the engine's maximum power is far beyond what is normally used and the engine operates at 5-25% load most of its life.
The diesel engine is more efficient at part load than the gasoline engine; however the 2000+ bar fuel injection system, variable geometry turbocharger(s) system, and emissions after-treatment have made the modern passenger vehicle diesel engine quite expensive. High levels of EGR to reduce NOX, SCR catalysts, and diesel particulate filters all negatively impact the engine efficiency. In addition, the price of diesel fuel relative to gasoline often negates any cost savings from the inherent higher efficiency of the engine for the end user.
The gasoline engine is still relatively inexpensive, and due to the 3 way catalyst, it is a very clean engine and full load efficiency can reach 35%. Unfortunately, the part load performance is extremely poor, with thermal efficiency dipping into single digits during much of its operation and seldom reaching 20% or higher. An idling gasoline engine with the vehicle running its air conditioning, power steering, and entertainment system has significant energy losses from throttling, engine friction accessory parasitic losses and cooling losses and uses fuel at a very high rate.
Perhaps an even larger impact than the direct pumping work, the engine system's Compression Ratio (CR) and Expansion Ratio (ER) are reduced. Thermodynamic cycles (such as the Otto cycle) are often used to characterize various engine types, however these cycles are different than the actual engine mechanical cycle that is seen on a PV diagram. The fact that a PV diagram of the actual engine cycle looks similar to the thermodynamic cycle adds to the confusion. In the thermodynamic cycle, the compression ratio and expansion ratio are characterized on the X-axis, i.e. Volume Ratio. This does not account for the induction and exhaust processes. If it did, then those processes would have to happen instantaneously at top dead center and bottom dead center with no pressure drop and the connecting reservoir would have to be at the same pressure and temperature, i.e. no throttling on the inlet or back pressure on the exhaust.
The theoretical volume ratio of an engine is not indicative of real efficiency when intake valves and exhaust valves open at various times during the compression and expansion processes, and an engine can throttled down to 0.1 bar in the intake manifold while the exhaust manifold is greater than 1 bar. The limitations of using thermodynamic cycles to draw conclusions about real engines are particularly severe when considering part load operation of a throttled gasoline engine.
In the real engine, power is produced by the expansion of the hot gas; the compression of the cold air is a necessary parasitic loss. These powers, one positive and one negative, are a function of the compression ratio and expansion ratio as calculated on the Y-axis (Pressure Ratio).
In a closed thermodynamic cycle, there is a fixed relationship between P and V, i.e. PV=mRT. In an open cycle engine with valves, this relationship does not exist, therefore the thermodynamic cycles are not really simplified representations of real operating cycles.
The efficiency of the simplified thermodynamic cycle that represents this engine, the Otto cycle, is a function of compression ratio
η=1−1/CR(γ−1) where
Looking at a highly throttled operating point as shown in
The engine friction comes from a great number of components; rings, pistons, rod bearings, crankshaft bearings, and the valve train (cam bearings, tappets, valves, and gears or chain). The oil pump parasitic loss can be book kept here as well. As known in the art, the rings and pistons account for about ½ of the friction loss as shown in
FMEP=a+(b*Pcyl)+(c*v2)
Thus an engine at 2000 rpm accelerating at full load has essentially the same friction loss as an engine at 2000 rpm at 10% load (cruising at moderate speed). If the output of the engine is 40 kW and the friction loss is 2 kW, then it's a 5% effect. If the output of the engine is at 4 kW, and the friction loss is still 2 kW, then it's a 50% effect. This fact shows why cylinder deactivation schemes bring only marginal benefit. The pistons, rings, crank, and valve train are still contributing very nearly the same parasitic loss as they would be if all the cylinders were activated.
It is therefore desirable to provide a gasoline internal combustion engine which reduces losses from throttling and engine friction.
The embodiments of the present application describe a variable stroke and compression ratio engine which employs multiple pistons connected to a wobbler. A crank with an axis of rotation has an upper journal with a first angle relative to the axis and a lower journal with a second angle with respect to the axis. A cradle connected for rotational motion with respect to the wobbler is carried by the crank with sliding engagement to the upper and lower journals for translation between a first high eccentricity position and second low eccentricity position.
Carrying the wobbler on the crank for actuation by the pistons allows translating the wobbler relative to the first angled journal on the crank to adjust bottom dead center position of the pistons, altering the stroke, and simultaneously translating the wobbler relative to the second angled journal on the crank for adjusting top dead center position of the pistons, thereby adjusting the compression ratio.
These and other features and advantages of the present invention will be better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:
6B and 6C are side section views of the exemplary embodiment of
Referring to the drawings,
A wobbler 42 is connected to the cradle 32 using bearings 44a, 44b and is connected to the engine bedplate 16 through an anti-rotation mechanism to be described in greater detail subsequently. The bedplate or case for the engine disclosed in the embodiments herein is solely for exemplary purposes. The actual shape and configuration of the bedplate may be altered as required to accommodate engine mounting, cooling system passages, auxiliaries such as oil pump and water pump and other interface applications. The rotation of the cradle and associated control elements and the constraining anti-rotation feature cause the wobbler to create a sinusoidal motion at each of its connections to connecting rods 46. The connecting rods are connected to the wobbler through ball and socket big end rod bearings 48 to accommodate the required degrees of freedom for motion of the wobbler. In alternative exemplary embodiments hydrostatic, hydrodynamic bearings or rolling element anti-friction bearings may be employed.
Connecting rods 46 are driven by pistons 8 and connected by the little end bearings 52 which are also ball and socket bearings. For the embodiment shown, the static structure of the engine consists of the bedplate 16, the cylinder block 14, and the cylinder liners 54. One skilled in the art may note that the engine could be configured with integral cylinder bores or with wet or dry liners.
Details of the operating elements of the engine are shown in
Bearings 48 also must also accommodate rotation in the YZ plane which is created by the wobbler going from TDC to BDC in adjacent cylinder assemblies. Additionally, bearings 48 must accommodate rotation of the wobbler in the XZ plane because the center of the wobbler in a plane containing the center points of the four rod big ends bearings is not on the center of rotation of the crankshaft, so the center of the wobbler in the aforementioned plane creates a circle through one 360 degree rotation. The diameter of this circle is variable, increasing with increased stroke.
Rotation in the XY, YZ, and XZ planes requires 6 degrees of freedom in this joint. Therefore any two combinations of 2 dimensional joints (translating or rotating) cannot provide sufficient freedom of movement. A ball and socket joint will provide this freedom to accommodate the required motion.
Similarly, the rod little end bearing 52 must accommodate more than the two degrees of freedom associated with a conventional wristpin joint. As piston 8 approaches mid-stroke, there is an angle in the XY plane that must be accommodated. In addition, the crank is offset in the Z direction creating the stroke for adjacent pistons. Therefore the little end joint must accommodate an angle in the YZ plane concurrently to the angle in the XY plane. Thus, more than 2 degrees of freedom are required.
For the embodiment shown, the crankshaft 10 extends through the engine cylinder block 14 and bedplate 16 carried in bearings 12a and 12b respectively and has a gear 56 mounted to drive the valve train (not shown) for combustion air and exhaust communication with the cylinders in a substantially conventional piston head (generally designated 55). Conventional IC engine practice can be used to design the cylinder heads and valve train in a multitude of configurations. In alternative embodiments, the helical gear valve train driven by gear 56 is replaced by a pushrod valve-train driven by an axial cam or electronic valve actuation.
As shown in
The mechanism at full stroke, thus full power at a given engine speed, is shown in
When the engine is at partial load as shown in
As shown in the PV diagram of
Returning to the first embodiment, lower journal 18 and upper journal 24 on the crankshaft function separately based on the associated angle α and β with the upper journal adjusting the position of the piston at Top Dead Center (TDC) and the lower journal adjusting the position of the piston at Bottom Dead Center (BDC). The maximum displacement is a function of the lower journal angle β (angle to the centerline of the crankshaft). The relationship of compression ratio (CR) to the displacement is a function of the upper journal angle α. While this angle can be chosen to maintain a substantially fixed CR, it also can be chosen to optimize the CR as a function of engine load.
To preclude instability or efficiency loss through undesired rotation of the wobbler in conjunction with the crank shaft, an anti-rotation device is employed as shown in
As for all engine configurations employing a driven cam arrangement, friction forces in the wobbler-cradle interface and the main bearings have a significant effect on operation. Hydrodynamic bearings and rolling element bearings are employed in exemplary embodiments as disclosed herein. As shown in
As the stroke of the engine is reduced, the friction forces associated with the wobbler-cradle become large. However, this is only a portion of the friction and is offset with the extreme reduction of reciprocating speed and associated friction allowed by the disclosed embodiments as previously described. The highest engine friction is due to the piston and rings. Friction is a function of (speed)2. At 25% stroke, the piston speed is reduced by a factor of 4 as shown in
Having now described the invention in detail as required by the patent statutes, those skilled in the art will recognize modifications and substitutions to the specific embodiments disclosed herein. Such modifications are within the scope and intent of the present invention as defined in the following claims.
Number | Name | Date | Kind |
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1968470 | Szombathy | Jul 1934 | A |
2532254 | Bouchard | Nov 1950 | A |
2539880 | Wildhaber | Jan 1951 | A |
4433596 | Scalzo | Feb 1984 | A |
Number | Date | Country | |
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20100300410 A1 | Dec 2010 | US |
Number | Date | Country | |
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61183015 | Jun 2009 | US |