This patent disclosure relates generally to internal combustion engines and, more particularly, to pistons operating within engine bores.
Internal combustion engines include one or more pistons interconnected by connecting rods to a crankshaft, and are typically disposed to reciprocate within bores formed in a crankcase, as is known. A typical piston includes a head portion, which at least partially defines a combustion chamber within each bore, and a skirt, which typically includes a pin opening and other support structures for connection to the connecting rod of the engine. In general, a piston is formed to have a generally cupped shape, with the piston head forming the base, and the skirt portion being connected to the base and surrounding an enclosed gallery of the piston. In typical applications, lubrication oil from the engine is provided within the gallery of the piston during operation to convectively cool and lubricate various portions of the piston.
A typical piston head also includes an outer cylindrical wall having one or more circumferentially continuous grooves formed therein. These grooves typically extend parallel to one another and are appropriately sized to accommodate sealing rings therewithin. These sealing rings create sliding seals between each piston and the crankcase bore it is operating within. Typically, the groove located closest to the skirt of the piston accommodates a scrapper ring, which is arranged to scrape oil clinging on the walls of the piston bore during a down-stroke of the piston. Oil that may remain wetting the walls of the bore following the down-stroke of the piston may enter the combustion chamber and combust during operation of the engine.
One known solution for improving the removal of oil found on the bore walls during a down-stroke of the piston can be seen in U.S. Pat. No. 6,557,514, which is incorporated herein in its entirety by reference (hereafter, “the '514 patent”). The '514 patent discloses a piston having an outer wall defined in part by a ring belt and including an oil gallery defined internally to the piston. An oil drainage groove is machined into the outer surface of the ring belt of the cylindrical side wall of the piston head, below two piston ring seal grooves. The oil drainage groove is partially defined by a bottom wall that extends circumferentially about the piston but is interrupted such that oil gathered in the oil groove can drain downwardly back into the crankcase of the engine. An upper wall of the oil drainage groove extends about the circumference of the body of the piston. As disclosed in the '514 patent, the upper ring grooves accommodate piston rings, while the bottom-most groove is free of piston rings and is arranged to collect oil as the piston undergoes a down-stroke.
The oil collection groove disclosed in the '514 patent is at least partially effective in reducing the amount of oil left behind on the cylinder wall after the piston has undergone a down-stroke.
With the foregoing as background, it is sometimes the case that a mature engine design, especially one that is already sold to consumers, is in need of improvements in performance, cost, or sourcing of components, which will render the engine more successful in the marketplace. Such product improvements for engines are especially valuable to an engine manufacturer if reverse compatibility of new components to be used in place of original engine components is preserved. Nevertheless, it has traditionally been the case that engine pistons are not considered as components that may be redesigned mid-stream through the product life cycle of a particular engine.
The unsuitability of engine pistons as components that may be redesigned to fit an existing engine and replace an existing, baseline piston design is because, in large part, design changes made to a piston will often require a cascading series of changes to other engine components. For example, a design update to a piston may cause changes to the weight balancing, performance, and/or any other functional attribute of the piston, which in turn will necessitate changes to the counterweights of the crankshaft, or changes to connecting rods and to engine calibration. Moreover, it is conceivable that engine overhaul service providers may replace some pistons but leave others with less wear or damage alone which would cause serious performance problems if the replacement piston was a different weight as compared to the original piston. Any such changes to the design of engine components renders retrofitting of certain components, such as pistons, effectively unsuitable for current-production engines.
This disclosure relates to pistons for use in internal combustion engines and, particularly, direct injection compression ignition engines. Particularly, the disclosure provides a method of achieving a design of pistons that are reverse compatible with engines having baseline pistons already in service. As used herein, reverse compatibility refers to the ability of interchangeably using original or baseline pistons and retrofit pistons using tooled piston blanks without requiring changes in other engine components. Thus, such retrofit or redesigned pistons may be used during new engine construction, or even to replace baseline pistons during service. Additionally, retrofit pistons may be arranged as after-market parts to improve the performance of existing engines.
Two examples or prior art pistons 10 and 20 are presented, respectively, in
The baseline piston 18 shown in
104 thereof from a body portion 106. An enclosed oil cooling gallery 102 is formed within the head portion 104 and is enclosed by an annular ledge 14. For purpose of the present disclosure, the baseline piston 18 will be considered as a baseline component that is suitable for a particular engine application and which has already been installed on engines sold to customers and operating in the field. For various reasons, such as component cost, availability of after-market or service parts, or desired engine performance improvements, an engine manufacturer may desire to replace the baseline piston 18 with an improved piston but without the need to further replace other engine components that are associated with the piston, such as the crankshaft.
Regarding component replacement at service or overhaul certain components such as pistons may be scheduled to be replaced at certain service intervals or at least inspected and replaced if wear is excessive. Pistons and piston rings are commonly replaced at overhaul however others such as the crankshaft and camshaft are not commonly replaced if possible. When a piston is to be replaced during such service event certain aspects of the baseline piston should be preserved and certain aspects of the replacement piston should not be substantially different from the baseline piston to ensure proper performance and emission control. The replacement piston should be “weight-balanced” or generally the same weight as the baseline piston. The replacement piston should have a substantially similar combustion bowl as the baseline piston and the ring groove geometry and placement should be similar to ensure proper performance and emissions control.
A piston blank 20 is shown in
Two embodiments of improved pistons suitable for retrofitting are disclosed herein. Each of the improved pistons illustrates a weight balancing operation performed on a piston blank to match the weight of a baseline piston. For instance, more weight has been removed from the piston 200 (as shown in
In each piston, the body portion 106 forms two pin bores 107. The head and body portions 104 and 106 of the pistons 100 and 200 may be frictionally welded to one another along seams 108. Each piston 100 or 200 defines an outer cylindrical wall 110 that extends over the head and body portions 104 and 106 as is best shown in the detail section of
A plurality of ring grooves that extend parallel to one another across a periphery portion of the outer cylindrical wall 110 includes an upper piston ring groove 118 disposed closest to the top face 116, a lower piston ring groove 120 disposed, as shown, below the upper piston groove 118, and a first oil collection groove 122 disposed below the lower piston ring groove 120. The upper and lower piston ring grooves 118 and 120, as well as the first oil collection groove 122, segment the outer cylindrical wall 110 into a plurality of “lands” or, stated differently, bands of cylindrical wall surface separating and spacing apart the grooves 118, 120, and 122. More particularly, a first or upper land 124 is defined between the upper piston ring groove 118 and the transition to the top face 116, a second land 126 is defined between the upper and lower piston ring grooves 118 and 120, and a third land 128 is defined between the lower piston ring and the first oil collection grooves 120 and 122, although other configurations or number of piston ring and oil collection grooves may be used.
As can be seen from the figures, the first, second, and third lands 124, 126, and 128 are generally aligned with the outer cylindrical wall 110. In other words, points on the first, second, and third lands 124, 126, and 128 are all at about the same radial distance from a centerline 130 of the piston 100 or 200, without regard to any draft angles or other variations to the cylindrical shape of the outer cylindrical wall 110 that may be present in the piston.
When installed in an engine, each piston 100 or 200 is disposed within a cylinder bore (not shown) and includes a combustion ring seal (not shown) that is placed within the first or upper piston ring groove 118 in sealing contact between the piston 100 or 200 and the cylinder bore. The combustion ring seal operates to fluidly separate combustion byproducts and combustible mixtures present within the cylinder above the piston. An oil scrapper ring (not shown) may be disposed within the lower or second piston ring groove 120. The scrapper ring may operate to scrape oil clinging to the walls of the cylinder during a down-stroke of the piston, as previously discussed. Oil collected by the scrapper ring may be, at least temporarily, collected in the first oil collection groove 122 before draining back down the piston into the crankcase of the engine (not shown). In the illustrated embodiments, one or more drain openings 132 fluidly connect the first oil collection groove 122 with the enclosed cooling gallery 102, which permits oil collected in the groove 122 to drain through the piston into the crankcase of the engine.
The description thus far has discussed features of the pistons 100 and 200 that are commonly found on the baseline piston 18 (
The piston 100 includes an additional or second oil collection groove 300, which is best shown in
In the specific embodiment of the piston 100 illustrated in
Similar to the piston 100, the piston 200 shown in
In the specific embodiment of the piston 200 illustrated in
The on-engine performance of the disclosed embodiments for the pistons 100 and 200 was evaluated and compared to the performance of the baseline piston 18 previously used on those same engines. The results of this comparison showed an unexpected improvement in the operation of the engines relative to certain engine operating parameters that can affect the efficiency of operation of the engines, as well as certain parameters affecting the reliability and longevity of the engines. In sum, it is believed that the additional oil collection grooves, for example, the second oil collection groove 300 of piston 100 (see, e.g.,
The first area of unexpected improvement in the operation of the pistons 100 and 200 relates to peak temperatures observed along the rim 117 of the combustion bowl 114 (see, e.g.,
Another area of unexpected improvement in the operation of an engine having the pistons 100 or 200 installed and operating therein relates to the oil “consumed” by the engine. As is known, engine oil consumption during operation of the engine can be attributed to various factors, which include oil vaporizing within the engine crankcase that is removed via a crankcase ventilation system, oil passing through the seals of the piston and entering the combustion cylinders, and other factors. It has been determined that the improved pistons 100 or 200 yield a 50% or more reduction in engine oil consumption as compared to a baseline piston. For instance, an engine operating at a rated condition for about 250 hours may consume oil at a rate of about 0.0005 pounds of oil (about 0.002 kg) per horsepower-hour of operation with the baseline piston. A test using the same engine operating under the same conditions for the same time period, but having either the improved piston 100 or the improved piston 200 installed therein, yielded a rate of oil consumption that was about 0.00024 pounds (about 0.0009 kg) of oil for every horsepower-hour, which represents a reduction of about 52% in the rate of engine oil consumption over the baseline piston design.
An additional example of improved engine operation using the pistons 100 or 200 was observed. Following a tear down of test engines containing the baseline pistons, as well as of engines containing the improved pistons 100 or 200, a considerable reduction of the amount of oil deposits accumulated in the first or upper piston ring groove 118 and on the second land 126 (see, e.g.,
Based on the foregoing, it can be appreciated that the width of the second oil collection groove 300 or 400 (as shown, respectively, in
It will be appreciated that the foregoing description provides examples of the disclosed system and technique. However, it is contemplated that other implementations of the disclosure may differ in detail from the foregoing examples. All references to the disclosure or examples thereof are intended to reference the particular example being discussed at that point and are not intended to imply any limitation as to the scope of the disclosure more generally. All language of distinction and disparagement with respect to certain features is intended to indicate a lack of preference for those features, but not to exclude such from the scope of the disclosure entirely unless otherwise indicated.
This patent application claims the benefit of U.S. Provisional Patent Application No. 61/256,894 filed Oct. 30, 2009, which is incorporated herein in its entirety by reference.
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