Piston arrangement and internal combustion engine
10240559 ยท 2019-03-26
Assignee
Inventors
Cpc classification
F16C2360/22
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B2075/027
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C31/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M35/10157
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16J1/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B2075/025
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B75/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01B9/023
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02F3/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02T10/12
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F01B7/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04B17/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F01B9/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02F3/28
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16C31/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02M35/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B75/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16J1/10
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02B75/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A piston arrangement comprising: a piston, a first chamber, a second chamber and a power transfer assembly; wherein the piston comprises a first head movable within the first chamber and a second head movable within the second chamber; wherein, in operation, the piston follows a linear path in reciprocating motion along a first axis; wherein the power transfer assembly comprises a shaft rotatably coupled to a shuttle bearing and arranged to convert the reciprocating motion of the piston to rotary motion of the shaft; wherein the shuttle bearing moves relative to the piston in reciprocating motion along a second axis substantially transverse to the first axis; and wherein the shuttle bearing is coupled to the piston via a non-planar bearing surface thereby allowing rotation of the shuttle bearing.
Claims
1. A piston arrangement comprising: a piston, a first chamber, a second chamber and a power transfer assembly; wherein the piston comprises a first head movable within the first chamber and a second head movable within the second chamber; wherein, in operation, the piston follows a linear path in reciprocating motion along a first axis; wherein the power transfer assembly comprises a shaft rotatably coupled to a shuttle bearing and arranged to convert the reciprocating motion of the piston to rotary motion of the shaft; wherein the shuttle bearing moves relative to the piston in reciprocating motion along a second axis substantially transverse to the first axis, and wherein the first chamber has the same diameter as the second chamber, and the first head has a different outer diameter to that of the second head.
2. A piston arrangement according to claim 1, wherein the shuttle bearing comprises one or more convex bearing surfaces.
3. A piston arrangement according to claim 2, wherein the piston comprises one or more concave bearing surfaces corresponding to the one or more convex bearing surfaces of the shuttle bearing.
4. A piston arrangement according to claim 1, wherein an interface between the piston and the shuttle bearing appears circular or part circular when viewed in the direction of the second axis.
5. A piston arrangement according to claim 1, wherein an interface between the piston and the shuttle bearing is cylindrical or part cylindrical or spherical or part spherical.
6. A piston arrangement according to claim 1, wherein the piston comprises a bore extending through its thickness in a direction substantially parallel to the second axis, and wherein the shuttle bearing is received in the bore.
7. A piston arrangement according to claim 1, wherein the piston comprises a slot extending through its thickness in a direction substantially perpendicular to the second axis, and wherein the shaft is received in the slot.
8. A piston arrangement according to claim 1, wherein the shuttle hearing substantially cylindrical or part-cylindrical and has a longitudinal axis parallel to the second axis.
9. A piston arrangement according to claim 1, wherein at least one bearing surface of the piston and/or shuttle bearing comprises one or more grooves formed in the bearing surface.
10. A piston arrangement according to claim 1, wherein the shaft is rotatably coupled to the shuttle bearing at an eccentric portion of the shaft.
11. A piston arrangement according to claim 1, wherein the second head is rigidly held in fixed relation to the first head.
12. A piston arrangement according to claim 1, wherein the second head is integrally formed with the first head.
13. A piston arrangement according to claim 1, wherein the first head and the second head face away from each other in, opposite directions.
14. A piston arrangement according to claim 1, wherein the first head and the second head are both centred on the first axis and each move in reciprocating motion along, the first axis.
15. A piston arrangement according to claim 1, wherein the shuttle bearing directly or indirectly engages the piston.
16. A piston arrangement according to claim 1, wherein the shuttle hearing contacts a reverse face of the first and/or the second piston head.
17. An internal combustion engine comprising a piston arrangement according to claim 1, wherein the first chamber is a combustion chamber.
18. An internal combustion engine according to claim 17, wherein the internal combustion engine is a two-stroke or four-stroke engine.
19. An internal combustion engine according to claim 17, wherein the second chamber is a supercharging chamber arranged to supply inlet air to the combustion chamber.
20. An internal combustion engine according to claim 19, further comprising a transfer port extending between the supercharging chamber and the combustion chamber, wherein the transfer port has an outlet at the combustion chamber which is opened and closed by the reciprocating motion of the first head.
21. An internal combustion engine according to claim 20, further comprising an oil seal mounted to a cylinder wall of the first chamber.
22. An internal combustion engine according to claim 21, wherein the oil seal is mounted to the cylinder wall on the opposite side of the transfer port to the combustion chamber.
23. An internal combustion engine according to claim 22, wherein the first head comprises an extended piston skirt which remains in continuous contact with the oil seal during reciprocating movement of the piston.
24. An internal combustion engine according to claim 20, further comprising a gas seal mounted to the first head.
25. An internal combustion engine according to claim 24, wherein the gas seal is positioned such that it passes the outlet of the transfer port during operation of the engine.
26. An internal combustion engine according to claim 17, wherein the power transfer assembly is housed within an intermediate chamber located between the first, and second chambers.
27. An internal combustion engine according to claim 26, wherein the intermediate chamber is sealed to substantially prevent the passage of fluid past the first and/or second head into or out of the first and/or second chambers.
28. A piston arrangement according to claim 1, wherein the shuttle hearing is coupled to the piston via a non-planar bearing surface thereby allowing rotation of the shuttle bearing.
29. A piston arrangement according to claim 28, wherein the non-planar bearing surface is arranged to allow rotation of the shuttle bearing about the second axis and/or about a third axis which is substantially transverse to the first and second axes.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Embodiments of the invention will now be described with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION OF EMBODIMENT(S)
(11)
(12) The casing 2 includes a first bore 6 and an upper wall 7 defining in part a working cylinder or combustion chamber 8. The casing 2 further includes a second bore 9 and a base wall 10 defining in part a supercharging cylinder or supercharging chamber 11. An intermediate chamber 12 is defined between the combustion chamber 8 and the supercharging chamber 11. The upper wall 7 has a threaded bore in which a spark plug 40 is fitted. The base wall 10 is curved inwardly into the supercharging chamber 11.
(13) The combustion chamber 8 is connected to the supercharging chamber 11 by a transfer port 15 having an inlet 16 at the supercharging chamber and an outlet 17 at the combustion chamber. The combustion chamber 8 also has an exhaust port 21 connected to an exhaust duct 22, as shown in
(14) The piston 3 includes a first head or working head 23 which is movable within the first bore 6 and has a working face 24 which forms the lower boundary of the combustion chamber 8. The working head 23 has an extended piston skirt extending away from the working face 24. An oil seal 14 is mounted to the piston skirt sufficiently far from the working face 24 that it does not pass the intake and exhaust ports 17 and 21 during reciprocating motion of the piston 3. Alternatively a static oil seal may be mounted to the wall of the combustion chamber 8 and the skirt of the working head 23 may maintain continuous contact with the oil seal during reciprocating motion of the piston 3. The working head has gas seal rings 26 fitted in grooves formed in its cylindrical outer surface which provide a gas-proof seal between the working head and the first bore 6.
(15) The piston 3 also includes a second head or supercharging head 27 which is movable within the second bore 9 and has a working face 28 which forms a movable upper boundary of the supercharging chamber 11. The supercharging head 27 has gas seal rings 31 and a second oil seal ring 32 fitted in grooves formed in its cylindrical outer surface which provide a gas-proof and oil-proof seal between the supercharging head and the second bore 9.
(16) The piston 3 further includes a circular bore 30 extending through its extent and having an axis 30 (the second axis) substantially transverse to the piston axis 3. The piston 3 further includes a slot 38 extending through its extent in a direction substantially perpendicular to the piston axis 3 and to the second axis 30. The supercharging head 27 is connected to the working head 23 by four linking elements 29, which together define the bore 30 and the slot 38.
(17) The shuttle bearing 4 is received within the bore 30 and has first and second part-cylindrical bearing surfaces 33 which engage the bore of the piston 3. The bearing surfaces 33 are provided with recessed grooves 45a or 45b (shown in
(18) As best shown in
(19) The piston 3 is movable relative to the casing 2 in reciprocating motion in the direction of its axis 3 between a top dead centre position (TDC), as shown in
(20) As the piston 3 moves along its axis 3 in reciprocating motion between TDC and BDC, the part-cylindrical bearing surfaces 33 of the shuttle bearing 4 remain in sliding contact with the bore 30 of the piston 3, and the shuttle bearing 4 moves with the piston in the direction of the piston axis. The eccentric portion 36 additionally causes the shuttle bearing 4 to move relative to the piston along a movement path substantially aligned with the second axis 30 in reciprocating motion. The shuttle bearing 4 generally follows a circular path 39 about the centre-line of the shaft 5, and moves with the centre point of the rotating eccentric portion 36, as indicated in
(21) The linear to rotary power transfer mechanism (including the bore 30 of the piston 3, the shuttle bearing 4 and the output shaft 5) is located within the intermediate chamber 12. The intermediate chamber 12 does not form part of the intake system for the engine 1 and is substantially sealed from the combustion chamber 8 and the supercharging chamber 11 by the gas seal rings 26,31 and the oil seal rings 14,32.
(22) The engine has a lubrication system which lubricates the power transfer mechanism within the intermediate chamber. Part of the lubrication system is shown in the cross section view of
(23) The engine 1 includes a counterbalancing system (not shown) to counteract vibrations due to piston acceleration at TDC and BDC. The counterbalancing system is located outside the intermediate chamber 12 at or adjacent a flywheel. In alternative embodiments the counterbalancing system may be located inside the intermediate chamber 12.
(24) Starting from BDC, the engine operates as follows: a) As the piston moves from BDC to TDC (
(25) The shuttle bearing and output shaft power transfer assembly of the invention provides a more compact, more robust and lighter weight linear to rotary motion coupling than the crankshaft and con rod arrangement of a standard two-stroke engine. The invention therefore allows an increase in strength and reduction in the size and weight of an engine so that power density and reliability is maximised.
(26)
(27) By increasing TDC dwell time combustion efficiency is increased, for example more complete combustion of the fuel in the combustion chamber is allowed to occur, so that fuel consumption is reduced and emissions of unburnt hydrocarbons are reduced. In addition spark advance may be reduced and the engine may be allowed to run at higher engine speeds.
(28) By reducing TDC piston acceleration, the engine 1 experiences reduced piston acceleration spikes at TDC and therefore reduced component loading. Therefore design requirements are reduced, so that the weight of the engine may be minimised. Reducing component loading also reduces wear rates and reduces the probability of early component failures, so the engine is more reliable, and has reduced maintenance requirements and repair costs.
(29) Moving the piston 3 in simple harmonic motion also eliminates the difference in piston acceleration at TDC and BDC so that counterbalancing requirements at TDC and BDC are equalised. In this way a counterbalancing system may be provided for the engine 1 which balances piston acceleration both at TDC and BDC without having to compromise between balancing different accelerations at TDC and BDC.
(30) By replacing the con rods of a standard two-stroke engine with a shuttle bearing arrangement, the invention eliminates the piston side load generally imparted to a piston in a conventional two-stroke engine. By reducing or eliminating piston side loads the invention reduces frictional losses of the engine so that efficiency is increased and reduces wear rates of the piston and cylinder side walls so that reliability is improved and maintenance costs are minimised.
(31) Due to the lubrication of the power transfer mechanism in the intermediate chamber 12 in isolation from the intake system, the engine does not require a total loss lubrication system as operated for conventional two-stroke engines. The cost of running the engine 1 is therefore reduced because it is not necessary to continually replace lubricating oil which is being passed out of the engine with exhaust gases. The engine 1 is also more environmentally friendly because oil is not passed out of the engine with the exhaust gases. The four-stroke style contained lubrication system also allows more efficient lubrication than in a conventional two-stroke engine so that wear rates are reduced and reliability is increased, thereby reducing maintenance costs for the engine.
(32) By using a dedicated supercharging chamber 11 to supply inlet air to the combustion chamber 8, the dimensions of the inlet system are not constrained by the geometry of the power transfer mechanism. The volume and shape of the supercharging chamber 11 may therefore be freely optimised to maximise engine performance and/or minimise fuel consumption and/or increase the range of engine speeds over which the engine delivers acceptable performance. The supercharging cylinder 11 may have the same or a different bore diameter to the combustion chamber 8.
(33) The supercharging chamber 11 provides a significantly smaller intake chamber with a higher volume ratio than the crankcase/intake chamber of a conventional two-stroke engine. The engine 1 therefore allows greater compression of the intake gases before delivery to the combustion chamber so that volumetric efficiency is improved, thereby increasing engine performance.
(34) By providing a separate supercharging chamber which does not house the power transfer assembly, the path of intake gases into and out of the supercharging chamber is simplified compared to a conventional two-stroke engine in which intake gases must pass the crankshaft, con rods and counterbalance weights. The volumetric efficiency of the engine is therefore increased.
(35) By locating the intake port 18 approximately centrally within the supercharging chamber 11 and facing towards the supercharging head 27, the engine efficiency with which intake gases are drawn into the supercharging chamber is maximised, thereby increasing volumetric efficiency of the engine. The improved volumetric efficiency of the engine due to the benefits associated with the supercharging chamber described above may significantly reduce the dependency of the engine on gas harmonics and thus increase the length of the engine's usable power-band. Therefore the overall dimensions and weight of the engine including its exhaust system downstream of the exhaust port 21 may be significantly reduced without sacrificing performance or fuel efficiency.
(36) A large contact area is provided between the piston 3 and the shuttle bearing 4 and between the shuttle bearing and the eccentric portion 36. By maximising the area across which the combustion force is applied from the piston 3 to the output shaft 5 the stress concentrations experienced by components in the power transfer mechanism are reduced. The reduced stress concentrations allow a reduction in the design requirements for the engine so that the weight of the engine may be minimised. The reduced stress concentrations also reduce component wear rates so the engine is more reliable and maintenance costs are minimised, especially compared to engines such as the Pattakon-Greco, Bourke or Revetec which transfer loads from a piston to a shaft via a point or line contact.
(37) The piston 3, shuttle bearing 4 and output shaft 5 are all comparatively simple components to machine using standard manufacturing techniques and tooling. The engine components are therefore less difficult and less expensive to manufacture than, for example, the cams used in a Pattakon-Greco engine, a Revetec engine or a Wankel engine, all of which require very precise machining of complex shapes.
(38) The part-cylindrical interface between the shuttle bearing 4 and the piston 3 allows the shuttle bearing to partially rotate about the second axis 30 within the bore 30. This allows the shuttle bearing to maintain good contact with the piston in the case of slight misalignment of any of the components in the power transfer assembly. The power transfer assembly is therefore more tolerant of manufacturing errors such as misalignment of axes including the axes of the output shaft 5 and/or the cylinder bore 6 and/or the bore 30 through the piston and/or the bore 34 through the shuttle bearing. These axes may therefore be machined slightly offset without hindering the durability and function of the engine.
(39) In order to permit assembly of the output shaft, shuttle bearing and piston, at least one of the output shaft and/or the piston may be provided as a split component.
(40) In an alternative embodiment shown in
(41) In the embodiment of
(42) In the embodiment of
(43) In a further alternative embodiment shown in
(44) In an alternative embodiment the shuttle bearing may have one or more part-spherical bearing surfaces allowing rotation about both an axis parallel to the direction of motion of the shuttle bearing(s) relative to the piston and an axis perpendicular to the piston axis and perpendicular to the direction of movement of the shuttle bearing(s) relative to the piston. This gives the combined advantage of increased tolerance of misalignment and wear of components and also increased TDC dwell time.
(45) Although the invention has been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope of the invention as defined in the appended claims. One or more of the features of any of the above embodiments may be combined with one or more of the features of any other embodiment.