This invention includes Zhou Engine and power-cam mechanism.
Zhou Engine is an engine which works as an internal-combustion engine and a combustion chamber of a gas turbine.
The primary purpose of inventing Zhou Engine is to increase thermal efficiency. This will reduce carbon emission and pollution, both are major issues in the current world. Also, raising the power density of power equipment would be reached.
A four-stroke diesel engine has the highest thermal efficiency of all current internal-combustion engines. The working process has intake stroke, compression stroke, expansion stroke (or power stroke) and exhaust stroke. The piston is driven by the crank-link mechanism. The piston-top motion curve (1H, in
Zhou Engine is partially similar to a conventional four-stroke engine in working principle. Zhou Engine also has intake stroke (1O), compression stroke (1P), expansion stroke (1R), and exhaust stroke (1S). And the valves action, fuel injection and spark ignition are the same as in four-stroke engine. The piston (3E, 9D) of Zhou Engine is in reciprocating motion in the cylinder (3D, 9L). But, Zhou Engine has the following exclusive characteristics:
1. A Zhou Engine comprises: shells (3C, 9B), many cylinders (3D, 9L), many pistons (3E, 9D), many toothed-roller arrays (3F, 9E, 9F), one power-cam (3B, 9C), a set of cylinder heads and valve timing mechanism and fuel supply system and ignition system.
2. Its piston-top motion curve (1H, in
3. Its work cycle (1T, in
4. To perform item 2 and 3 above, two examples of Zhou Engine are shown in drawings, example A (reference
5. In the drawings of
6. Comparison with four-stroke diesel engine, Zhou Engine has those advantages—the smoother airflow, the better combustion state, the less heat loss, the extra expansion, the less residual exhaust, the much fewer sliding friction—which are mentioned above. Supposing the effective efficiency of a four-stroke diesel engine is 40%, we estimate the effective efficiency of Zhou Engine would be 60%.
Power-cam mechanism is an improved cam mechanism.
Cam mechanism is a widely used in all mechanical fields. The cam is a rotating or sliding piece in a mechanical linkage, used especially in transforming rotary motion into linear motion or vice-versa. Because of its sliding frictions, its efficiency is low, and it is only suitable for motion transforming rather than driving force transforming.
This power-cam mechanism uses rolling motions as much as possible instead of sliding to reduce friction, especially between the follower (18C) and the casing (18D). It is suitable for driving force transforming as well as motion transforming.
The drawings of
Power-cam mechanism (18A, in
The power-cam (3B), which rotates round axle center (18H), drives the follower (18C) in reciprocation motion (18K) along a straight line or an arc, and vice versa. The casing (18D) and the axle center (18H) are stationary. A toothed-roller array (18E) is that many toothed-rollers (20F, 21F) are restricted and synchronized. A toothed-track (18I, 18J) has one bearing surface (20B, 20D, 21B, 21D), and has many teeth (20A, 20C, 21A, 21C). A toothed-roller (20F, 21F) is a roller with many teeth. Or rather, a toothed-roller (20F, 21F) has one bearing surface (20H, 21H) and many teeth (20G, 21G). The bearing surface (20H, 21H) is for rolling on the bearing surface of a toothed-track (20B, 20D, 21B, 21D). And the teeth (20G, 21G) are for meshing with the teeth of toothed-track (20A, 20C, 21A, 21C). While they are working, the toothed-roller array (18E), or rather the synchronized toothed-rollers (20F, 21F), roll (reference Detail F1) between the toothed-track of the follower (18I) and the toothed-track of the casing (18J), withstand the normal force on their bearing surface (20H, 20B, 20D, 21H, 21B, 21D) contacting, and mesh (20I, 20J, 21I, 21J) their teeth (20G, 20A, 20C, 21G, 21A, 21C), to keep the toothed-rollers always in the proper position and avoid sliding.
The tracks of the power-cam (18G) may be very complicated, that means the relationship between the follower (18C) motion and time is very complicated.
The tracks of the power-cam (18G) may have teeth (19K) if needed. If so, the wheels of the follower (19A, 19F) must have teeth (19C, 19H) corresponding to, to keep the wheels always rolling and avoid sliding, to prevent energy loss from the wheels sliding while speed changing. The wheels (19A, 19F) change speed periodically. The roller bearings of the wheels (19D, 19L) may be toothed roller bearings or preloaded roller bearings, to prevent their rollers from sliding while speed changing.
The toothed roller bearing mentioned above may comprise: an outer ring with toothed-track, an inner ring with toothed-track, many toothed-rollers, and a cage to restrict and synchronize the toothed-rollers. Its principle is similar to the co-working of toothed-tracks (18I, 18J) and synchronized toothed-rollers (20F, 21F).
All the teeth mentioned above, may be of involute profile.
Thus, power-cam mechanism (18A) has very few sliding frictions, which includes: between toothed-rollers (20F) and their cage (20E), and between meshing teeth. And the other frictions are all rolling ones. So it (18A) has much higher mechanical transforming efficiency than conventional cam mechanism and most crank-link mechanism. It is also able to transform very complicated follower (18C) motion. It can be used in all mechanical fields.
Zhou Engine mentioned above, has used power-cam mechanism (18A), showing in following:
In example A, reference
In example B, reference
The drawings in
The drawings in
The drawing in
Compared with
The parts list in table 3 above. The meanings of the symbols in this drawing are in the following table (table 11
This Zhou Engine comprises: 1 power-cam (3B), 2 shells (3C), 5 pairs of cylinders (3D), 5 pairs of pistons (3E), 40 toothed-roller arrays (3F), 1 set of cylinder head and valve timing mechanism and fuel supply system and ignition system (3S). It has 3 obviously characteristics as follows:
(a) The pistons (3E) work as pairs, at the same axial line, and in precise inverse motion.
(b) The one power-cam (3B) drives the all pistons (3E) by the tracks of the power-cam and the wheels mounted on the pistons (3E), and vice versa.
(c) The pistons (3E) are in reciprocating motion, and are confined by the cylinders (3D) and the toothed-roller arrays (3F).
A set of cylinder heads, valve timing mechanism, fuel supply system and ignition system, is essential, but is not shown in this drawing, and can be designed conventionally. That is similar to some radial engine. The difference is in the cams which drive the valves and fuel pumps. The cams can be direct fixed on the main shaft (3G) in this Zhou Engine. The intake valves open in the intake stroke, and close at all other times. The exhaust valves open in the exhaust stroke, and close at all other times. The fuel injection starts at the beginning of the combustion period (1Q), then spark ignite if needed. The intake valves, the exhaust valves, the fuel injections and the spark ignitions work the same as in a conventional four-stroke engine.
A Zhou Engine can be designed with any number of cylinders (3D).
The curvature of the tracks (4C) of the power-cam (3B) is designed according to the piston-top motion curve (1H, in
The vibration of this Zhou Engine can be removed by specifying the number of work cycles of the power-cam each round to be greater than one. But, if the number is greater than two, the solid mechanical parameters of this Zhou Engine will worsen.
Example A needs one power-cam (3B).
This shell has 20 toothed-tracks (3R), 1 shaft hole (5B), 10 through-holes (5C), 10 holes (5D). Each toothed-track (3R) has 1 bearing surface (3M), and many teeth (3N) in a row.
Example A needs two shells (3C).
This piston (3E) comprises: 1 big wheel (6A), 2 small wheels (6B), and 4 toothed-tracks (3Q). Each toothed-track has many teeth (3K) in a row, and 1 bearing surface (3J).
Example A needs 5 pairs of pistons (3E).
Example A needs 5 pairs of cylinders (3D).
A toothed-roller array (3F) is that a cage (3L) restricts and synchronizes many toothed-rollers (3I). A toothed-roller has 1 bearing surface (8A) and many teeth (8B). Or rather, a toothed-roller (3I) is a roller, but with teeth (8B). While they are working, the synchronized toothed-rollers (3I) roll between the toothed-track of the shell (3R) and the toothed-track of the piston (3Q), and mesh their teeth (8B, 3K, 3N).
Example A needs 40 toothed-roller arrays.
This Zhou Engine comprises: 3 pairs pistons (9D), 2 shells (9B), 1 power-cam (9C), 12 toothed-roller array A's (9E), 12 toothed-roller B's (9F). The number of cylinders (9L) equals that of pistons (9D). This engine has 3 characteristics as follow:
(a) The pistons (9D) work as pairs, at the same axial line, and precisely inverse motion.
(b) The one power-cam (9C) drives all the pistons (9D), and vice versa, by the tracks of the power-cam and the wheels mounted on the pistons.
(c) Each piston (9D) is in reciprocating motion, and is confined by the cylinder (9L) and toothed-roller arrays (9E, 9F).
The cylinder heads (9Q), valves (9O, 9P) actuating mechanism, fuel supply system, and ignition system, can be designed conventionally. The intake valves (9O) open in the intake stroke (1O), close in all other times, and are driven by the cams (9N). The exhaust valves (9P) open in the exhaust stroke (1S), close in all other times, and are driven by the cams (9N). The fuel injection starts at the beginning of the combustion period (1Q), then spark ignite if it's needed. The intake valve (9O), the exhaust valve (9P), the fuel injection and the spark ignition work the same as in a conventional four-stroke engine. The cams (9N) direct fixed on the main shaft (9G) of the power-cam (9C), and are synchronous rotation with the power-cam (9C).
Zhou Engine can have any number of pistons (or cylinders).
This shell (9B) comprises: 3 cylinders (9L), 12 toothed-tracks (9U), 6 through holes (10C), and 3 holes (10D). Each toothed-track has 1 bearing surface (10B), and many teeth (10E) in a row.
Example B needs two shells (9B).
The curvature of the tracks (11B) of the power-cam (9C) is designed according to the piston-top motion curve (1H, in
Example B needs one power-cam (9C).
This piston (9D) has one big wheel (9H), one small wheel (12A), and four toothed-tracks (9V). Each wheel (9H or 12A) has bearings (12B). The bearing (12B) is conical roller bearing. Each toothed-track (9V) has one bearing surface (12C) and many teeth (12D) arranged in a row, for the toothed-roller array (9E or 9F) rolling along.
Example B needs 3 pairs of pistons (9D).
Each toothed-roller array A (9E) comprises one cage A (13B) and many toothed-rollers (13A). Each toothed-roller array B (9F) comprises one cage B (13C) and many toothed-rollers (13A). Each the toothed-roller (13A) has 1 bearing surface (13E) and many teeth (13D).
Example B needs 12 toothed-roller array As (9E) and 12 toothed-roller array Bs (9F).
The meanings of symbols in following mathematical expressions are in table 14 above.
Basic assumption: Working substance is air, is the ideal gas, and its adiabatic index is 1.4; The initial values of p, T, V, F are shown in table 14 above; The compression ratio of this engine is 20; The maximum temperature of combustion is limited in 2500 K.
Of course, F is proportional to V.
Based on the above, this pV-diagram (pressure-volume diagram) is drawn in
Meanings of symbols in drawings of
The intake stroke is at 14I, and the exhaust stroke is at 14J, they are not drawn.
In this pV-diagram, its absorption heat in combustion period (14B) is 1.4796*V1 (MJ), it produces total work 1.1006*V1 (MJ), and its thermal efficiency is 74%. This pV-diagram also shows—its compression ratio is the same as Diesel engine, its combustion process is the same as Otto engine, and its expansion stroke is some likeness to a turbine which has full expansion.
Those points, 14E, 14F, 14H, are the joint points of Zhou Engine with multistage dynamic compressor and turbine.
Meanings of symbols in mathematical expressions are in table 14 above.
Meanings of symbols in this drawing are in table 14.1 above.
In this drawing, the appliance has two output shafts, one shaft on Zhou Engine (15F), and one shaft on turbine (15D). Or rather, the Zhou Engine (15G) works as a combustion chamber of gas turbine but has large extra power output. The gas flow behavior of the Zhou Engine is the key, which shows in
Meanings of symbols in mathematical expressions are in table 14 above.
The meanings of symbols in this drawing are in table 14.1 above.
This Zhou Engine (15G) has 5 pairs of pistons, and each of their intake strokes and exhaust strokes takes a quarter of cycle time (C/4). This means that intake stroke of each pair partial overlaps other pairs, and so does the exhaust stroke. Then we reason as the following:
(a) The curve within intake stroke is divided into 3 segments—s1(t), s(t), s2(t)—and each of them occupies different time interval. Then, the functions of these 3 segments are created in expression (1):
While this piston-pair is working on sl(t) and t∈[0, 0.05*C], the previous piston-pair is working on s2(t). Their works overlap and their phase difference is 0.2*C. So the intake air volume flow rate F(t):
While this piston-pair is working on s(t) and t∈[0.05*C, 0.2*C], it works alone, the intake air volume flow rate F(t):
While this piston-pair is working on s2(t) and t∈[0.2*C, 0.25*C], the next piston-pair is working on sl(t), their works overlap and their phase difference is 0.2*C. Or rather, the F(t) repeats the expression (2) on the next piston-pair, then we turn our viewpoint on next piston-pair as the power-cam rotates, and repeat reasoning expression (2) and expression (3) . . . .
Thus, the processes of expression (2) and expression (3) keep alternating and repeating as the power-cam rotating.
Therefore, F(t) equals 164.80/C*A at any time, which is a constant. So, the volume flow rate F(t) of intake of this Zhou Engine (15G), is very steady, has no pulsation, and can perfectly match the multistage dynamic compressor. This intake flow is much different from that in a conventional four-stroke engine.
We can deduce the following conclusions: any piston motion on expression (1), its position is continual, its speed is continual, and the absolute value of its acceleration is minimal. The deducing processes omit here.
(b) Following above analytical process, the curve within exhaust stroke, is divided into 3 segments—e1(t), e(t), e2(t)—and each of them takes different time interval. Then, the functions of these 3 segments are created in expression (4).
Following item (a) above, we can deduce that—the whole exhaust volume flow rate F(t) of this engine (15G) is very steady and has no pulsation. The deducing process omits here.
We can deduce the following conclusions: any piston motion on expression (4), its position is continual, its speed is continual, and the absolute value of its acceleration is minimal. The deducing processes omit here.
Therefore, the exhaust gas flow from this Zhou Engine (15G) fits to drive a turbine, and is much different with that from a conventional four-stroke engine.
According to item (a) and item (b), Zhou Engine could be a good combustion chamber of a gas turbine; more than that, it has an extra power output (15F), even greater than the original power output.
Note, the s1(t), s(t), s2(t), e1(t), e(t) and e2(t), are all exact functions.
(c) It needs just a small working volume (14E) V=0.1*V1 (conventionally V=V1) in this Zhou Engine for intake air from the compressor (15B, in
(d) Paying attention to the 14H in
To select the parameters of 14H, we must consider the catalysis exhaust purifying (15E, in
Conventionally, to increase thermal efficiency of gas turbine, we can increase the compression ratio and/or increase hot gas temperature. However the hot gas temperature is the difficult part. Now, we can use the Zhou Engine as its combustion chamber, and properly select the temperature of exhaust to fit the gas turbine. Since there are temperature limits in a cylinder and in a turbine, the temperature limit in a cylinder is much higher than that in a turbine. So, we use the cylinders of this Zhou Engine (15G) to withstand the higher temperature, to increase total appliance thermal efficiency.
(e) The smaller working volume is needed in this Zhou Engine as showing in item (c) and (d). That means—not only the volume of the engine gets much smaller, but also the rated speed can be much increase accordingly. This further enhances the power density of the whole appliance.
(f) It is only for easy analysis in this example that constant volume combustion at the 14B in
(g) It is only for easy analysis in this example, that adiabatic compression, in the multistage dynamic compressor (15B) in
This power-cam mechanism (18A) comprises: 1 power-cam (3B), 1 follower (18C), 1 casing (18D), and 4 toothed-roller arrays (18E). The power-cam (3B) has 3 tracks (18G), 1 shaft (18B). The follower (18C) has 3 wheels (19A, 19F), 4 toothed-tracks (18I). The casing (18D) is stationary and has 4 toothed-tracks (18J). Each toothed-roller array (18E) has many toothed-rollers (20F, 21F) which are restricted and synchronized.
There are 2 examples of toothed-roller arrays and the corresponding toothed-tracks. They are in
In this drawing, the toothed-roller array (18E) is that a cage (20E) restricts and synchronizes many toothed-rollers (20F). Each toothed-roller (20F) has 1 bearing surface (20H) and many teeth (20G) in a circle. Correspondingly, the toothed-track of the follower (18I) has 1 bearing surface (20B) and many teeth (20A) in a row; the toothed-track of the casing (18J) has 1 bearing surface (20D) and many teeth (20C) in a row. While they are working, the synchronized toothed-rollers (20F), roll between the toothed-track of the follower (18I) and the toothed-track of the casing (18J), withstand the normal force with their bearing surface (20H, 20B, 20D) contacting, and mesh (20I, 20J) their teeth (20G, 20A, 20C), to keep the toothed-rollers (20F) always in the proper position and from sliding.
In this drawing, the toothed-roller array (18E) is that many toothed-rollers (21F) are restricted and synchronized by the toothed-track of the follower (18I) and the toothed-track of the casing (18J). Each toothed-roller (21F) has 1 bearing surface (21H) and many teeth (21G) in two circles. Correspondingly, the toothed-track of the follower (18I) has 1 bearing surface (21B) and many teeth (21A) in 2 rows, and the toothed-track of the casing (18J) has 1 bearing surface (21D) and many teeth (21C) in 2 rows. While they are working, the synchronized toothed-rollers (21F), roll between the toothed-track of the follower (18I) and the toothed-track of the casing (18J), withstand the normal force with their bearing surface (21H, 21B, 21D) contacting, and mesh (21I, 21J) their teeth (21A, 21C, 21G), to keep the toothed-rollers (21F) always in the proper position and from sliding.
This drawing and
Filing Document | Filing Date | Country | Kind |
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PCT/CA2014/050106 | 2/14/2014 | WO | 00 |