Piston cooling configurations utilizing lubricating oil from a bearing reservoir in an opposed-piston engine

Abstract

Pressurized lubricating oil is accumulated in the bearings of opposed pistons and accumulated oil is dispensed therefrom for bearing lubrication and also for cooling the undercrowns of the pistons by jets of oil emitted from the bearings.

Claims

1. A piston cooling configuration for an opposed-piston engine, comprising: a piston with a crown having an end surface shaped to form a combustion chamber with an end surface of an opposing piston; the crown including an undercrown; a bearing mounted in the piston between the undercrown and a small end of a connecting rod; the bearing including a wristpin and a bearing surface; an oil reservoir in the wristpin in fluid communication with one or more wristpin oil outlet passages positioned to pass oil through the wristpin into a lubrication interface between the wristpin and the bearing surface; at least one oiling groove in the bearing surface which is in fluid communication with a wristpin oil outlet passage of the oil reservoir; a wristpin oil inlet passage in fluid communication with the reservoir; and, at least one cooling jet outlet in a part of the bearing that does not move relative to the undercrown; in which the cooling jet outlet is in fluid communication with the oil reservoir via the at least one oiling groove and is aimed toward an undercrown portion, further in which the oil reservoir is an annular recess with opposing ends and has an axis that corresponds to an axis on which the wristpin oscillates.

2. The piston cooling configuration of claim 1, in which the wristpin is received on the small end of the connecting rod.

3. The piston cooling configuration of claim 2, in which: the part of the bearing that does not move relative to the undercrown includes a bearing member supporting the wristpin for rotatable oscillation with respect to the undercrown in response to movement of the piston; and, the cooling jet outlet includes an oil outlet passage in the bearing member.

4. The piston cooling configuration of claim 3, in which: the connecting rod includes an oil passage in fluid communication with the wristpin oil inlet passage; and, the oil outlet passage in the bearing member receives pressurized oil from the at least one oiling groove.

5. The piston cooling configuration of claim 4, in which the wristpin and the bearing surface form a biaxial bearing.

6. An opposed-piston engine including at least one cylinder with longitudinally-separated exhaust and intake ports, a pair of pistons disposed in opposition to one another in a bore of the cylinder, and a pair of connecting rods, in which each piston is coupled to a respective connecting rod by a bearing, and at least one piston includes a piston cooling configuration according to any one of the preceding claims.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic drawing of a prior art opposed-piston engine with a pump-supplied oil gallery.

(2) FIG. 2 is a side view, in perspective, of a piston/connecting rod assembly for a two-stroke cycle, opposed-piston engine in which the piston has a first end surface construction.

(3) FIG. 3 is a cross-sectional view of the piston crown and skirt taken along lines A-A of FIG. 2.

(4) FIG. 4 is an exploded view of the piston/connecting rod assembly of FIG. 2 showing elements of a bearing configuration.

(5) FIG. 5A is a cross-sectional view of the piston/connecting rod assembly taken along lines A-A of FIG. 2 showing a first cooling jet outlet construction.

(6) FIG. 5B is a cross-sectional view of the piston/connecting rod assembly taken along lines B-B of FIG. 2 showing a second cooling jet outlet construction.

(7) FIG. 6 is a cross-sectional view of the crown and skirt of a piston having a second end surface construction.

(8) FIG. 7A is a cross-sectional view showing the piston of FIG. 6 assembled to a bearing with a first variation of the first cooling jet outlet construction.

(9) FIG. 7B is a cross-sectional view showing the piston of FIG. 6 assembled to a bearing with a variation of the second cooling jet outlet construction.

(10) FIG. 8 is a cross-sectional view of the piston/connecting rod assembly taken along lines A-A of FIG. 2 showing a cooling jet outlet construction for delivering one or more cooling jets to a central gallery of the piston.

DETAILED DESCRIPTION

(11) A two-stroke cycle engine is an internal combustion engine that completes a power cycle with a single complete rotation of a crankshaft and two strokes of a piston connected to the crankshaft. One example of a two-stroke cycle engine is an opposed-piston engine in which a pair of pistons is disposed in opposition in the bore of a cylinder. During engine operation, combustion takes place in a combustion chamber formed between the end surfaces of the pistons.

(12) As seen in FIG. 1, an opposed-piston engine 49 has at least one ported cylinder 50. For example, the engine may have one ported cylinder, two ported cylinders, three ported cylinders, or four or more ported cylinders. For purposes of illustration, the engine 49 is presumed to have a plurality of ported cylinders. Each cylinder 50 has a bore 52. Exhaust and intake ports 54 and 56 are formed in respective ends of the cylinder such that the exhaust port 54 is longitudinally separated from the intake port 56. Each of the exhaust and intake ports 54 and 56 includes one or more circumferential arrays of openings. Exhaust and intake pistons 60 and 62 are slidably disposed in the bore 52 with their end surfaces 61 and 63 opposing one another. The exhaust pistons 60 are coupled to a crankshaft 71, and the intake pistons 62 are coupled to a crankshaft 72. Each of the pistons is coupled to its associated crankshaft by a bearing 74 and a connecting rod 76.

(13) A lubrication system that supplies oil to lubricate the moving parts of the engine 49 includes an oil reservoir 80 from which pressurized oil is pumped by a pump 82 to a main gallery 84. The main gallery supplies pressurized oil to the crankshafts 71 and 72, typically through drillings 86 to the main bearings (not seen). From grooves in the main bearings, pressurized oil is provided to grooves in the big end bearings of the connecting rods 76. From there, pressurized oil flows through drillings 77 in the connecting rods to the bearings 74.

(14) In some aspects, which are not intended to be limiting, the engine 49 is equipped with an air management system 51 that includes a supercharger 110 and a turbocharger 120. The turbocharger has a turbine 121 and a compressor 122 rotating on a common shaft 123. The turbine 121 is coupled to the exhaust subsystem and the compressor 122 is coupled to the charge air subsystem. Exhaust gas emptied into the conduit 125 from the exhaust port 54 rotate the turbine 121. This rotates the compressor 122, causing it to generate charge air by compressing intake air. The charge air output by the compressor 122 flows through a conduit 126, whence it is pumped by the supercharger 110 to the openings of the intake port 56.

(15) The operational cycle of an opposed-piston engine is well understood. In response to combustion occurring between their end surfaces 61, 63, the opposed pistons 60, 62 move away from respective top center (TC) locations in the cylinder. While moving from TC, the pistons keep their associated ports closed until they approach respective bottom center (BC) positions. The pistons may move in phase so that the exhaust and intake ports 54, 56 open and close in unison; alternatively, one piston may lead the other in phase, in which case the intake and exhaust ports have different opening and closing times. As the pistons move through their BC locations exhaust products flowing out of the exhaust port 54 are replaced by charge air flowing into the cylinder through the intake port 56. After reaching BC, the pistons reverse direction and the ports are again closed by the pistons. While the pistons continue moving toward TC, the charge air in the cylinder 50 is compressed between the end surfaces 61 and 63. As the pistons advance to their respective TC locations in the cylinder bore, fuel is injected through the nozzles 100 into the charge air, and the mixture of charge air and fuel is compressed in the combustion chamber formed between the end surfaces 61 and 63 of the pistons 60 and 62. When the mixture reaches an ignition temperature, the fuel ignites. Combustion results, driving the pistons apart, toward their respective BC locations.

(16) In some cases, the opposing end surfaces 61 and 63 are identically constructed and the pistons 60 and 62 are disposed in rotational opposition with reference to the axis of the cylinder in which they are disposed. See, for example, the piston end surface constructions described and illustrated in the Applicant's US publication 2011/0271932 A1 and US publication 2013/0213342 A1. In some other cases, the opposing end surfaces 61 and 63 have complementary constructions which do not require rotational opposition. See, for example, the piston end surface constructions described and illustrated in the Applicant's WO publication 2012/158756 A1 and related U.S. application Ser. No. 14/026,931.

(17) It is desirable to include undercrown cooling in the thermal design of the pistons of an opposed-piston engine such as the engine 49 shown in FIG. 1. Therefore, the undercrown cooling embodiments described and illustrated in this specification may be combined with other modes of piston thermal management in order to realize an effective piston thermal performance. Undercrown cooling and other objectives are achieved by accumulating pressurized lubricating oil in the piston bearings of an opposed-piston engine and dispensing accumulated oil therefrom for bearing lubrication and also for cooling the undercrowns of the pistons by way of one or more jets.

First End Surface Construction

(18) FIG. 2 is a perspective view of a piston assembly used in an opposed-piston engine in which the pistons have identical end surfaces. In this case the description is directed to a single piston, with the understanding that it applies as well to its opposing counterpart. The piston assembly includes a piston 200 and its associated connecting rod 210. The piston 200 has a crown 203, and a skirt 205. An end surface 206 of the crown is configured to form a combustion chamber in cooperation with the end surface of an identically-configured, opposing piston. Lands and ring grooves 207 are provided in the crown's side wall. Referring to FIGS. 2, 3, and 4, the piston includes an undercrown 208, which is that portion of the piston crown 203 that is behind or underneath the end surface 206 against which combustion acts. The connecting rod 210 has a large end 211 for coupling to a crank throw of a crankshaft (not seen). An oil groove 212 is formed in the bearing surface of the large end 211. An oil delivery passage 213 (best seen in FIG. 5B) extends longitudinally in the connecting rod 210 from the oil groove 212 to the small end 215.

(19) As per FIGS. 2 and 3, the contour of the end surface 206 includes a ridge 209 formed by complex curved surfaces including a bowl 214 that interact with bulk air motion components to enhance charge air turbulence in the combustion chamber. During combustion, one or more hot spots may occur in portions of the crown including the ridge 209 and/or the bowl 214.

Piston Bearing Construction and Lubrication

(20) With reference to FIGS. 4, 5A, and 5B, the piston 200 includes a bearing 217 fixed to the undercrown 208 and disposed in space encircled by the skirt 205. As per FIGS. 4 and 5B, a bearing structure includes bearing support members 219a and 219b. The bearing support member 219a includes a bearing surface 220 that receives a wristpin 221 (also called a journal or a gudgeon pin) mounted to the small end 215 by threaded fasteners. In some instances, the bearing support members 219a and 219b are joined around the wristpin 221 and secured to the undercrown by fasteners 218 that are threadably seated in interior structures of the undercrown 208. As seen in FIG. 4, an opening 223 in the bearing support member 219b receives the connecting rod 210. When assembled, the bearing support member 219a, 219b retains the wristpin 221 for oscillation on the bearing surface 220 caused by arcuate oscillation of the connecting rod 210 in the opening 223.

(21) As per FIGS. 4 and 5B, the wristpin 221 includes an internal oil reservoir 222 in fluid communication with an oil inlet passage 224 drilled through the wristpin 221 and one or more oil outlet passages 225 drilled through the wristpin 221. Circumferential oiling grooves 227 are formed in the bearing surface 220 in alignment and fluid communication with the oil outlet passages 225. In some aspects, best seen in FIG. 4, the oil reservoir 222 can be configured as an annular recess with opposing ends and an axis that corresponds to the axis on which the wristpin 221 oscillates. In this case, a cylindrical shaft 250 is received in the cylindrical inner surface 228 of the wristpin 221. A flange 252 is fixed to one end of the shaft 250; the opposite end of the shaft is threaded to another flange 254 so as to retain the shaft 250 in coaxial alignment with the cylindrical inner surface 228 of the wristpin 221. As the views in FIGS. 4 and 5B show, the smaller diameter of the shaft 250 results in the formation of an annular space between itself and the inner surface 228. In other instances the oil reservoir may be formed by a capped or stoppered drilling in the wristpin 221.

(22) With reference to FIG. 5B, pressurized oil is transported to the large end oil groove 212 in the manner illustrated by the transport path 80, 82, 84, 86 in FIG. 1. From the oil groove 212, pressurized oil is delivered to the oil reservoir 222 via the oil reservoir inlet passage 224. Pressurized oil received in the oil reservoir 222 is provided in multiple streams through the outlet passages 225 to the oiling grooves 227 whence it flows to lubricate the bearing interface between the bearing surface 220 and the wristpin 221.

(23) In some aspects, but not necessarily, the bearing 217 may be constructed as a rocking journal bearing (also called a biaxial bearing). Such a bearing is described in the Applicant's U.S. patent application Ser. No. 13/776,656. In this case the bearing surface 220 comprises a plurality of axially-spaced, eccentrically-disposed surface segments and the wristpin 221 includes a corresponding plurality of axially-spaced, eccentrically-disposed wristpin segments. In such cases, the bearing surface 220 may have a semi-cylindrical configuration with two lateral surface segments sharing a first centerline and a central surface segment separating the two lateral surface segments and having a second centerline offset from the first centerline. In such cases, the circumferential oiling grooves 227 are formed in the bearing surface 220 at the borders between the central surface segment and the lateral surface segments. In some instances, the outer surface of the wristpin 221 may have axially-spaced circumferential grooves 226 (best seen in FIG. 4) and one or more circumferentially-spaced axial oiling grooves (not seen) may also be formed in the bearing surface 220 to enhance the lubrication of the bearing interface.

Gallery Cooling

(24) As best seen in FIGS. 3, 4 and 5A, the undercrown 208 is cooled by flow of lubricating oil through one or more galleries internal to the crown 203. Preferably, the galleries comprise shaped spaces in the undercrown 208 with floors provided on the upper surface of the bearing support member 219a. For example, an annular gallery 256 follows the periphery of the crown 203 and girds a central gallery 257. The annular gallery 256 communicates with the central gallery 257 through holes 258. The annular gallery 256 has an asymmetric profile that rises as at 260 under the ridge 209. The central gallery 257 abuts the deepest part of the end surface 206. Lubricating oil for cooling the undercrown is provided to the galleries via a high velocity jet of pressurized oil. The jet strikes the interior surface of the annular gallery at its highest point 260, thereby cooling that portion of the undercrown 208 beneath the ridge 209 by impingement. The oil carried by the jet flows from there throughout the annular gallery 256. From the annular gallery 256, the lubricating oil flows into the central gallery 257 where it continuously irrigates the central portion of the undercrown along the inside of the ridge 209. Lubricating oil flowing throughout the annular gallery 256 washes and cools an annular portion of the undercrown 208 that abuts the lands and ring grooves 207. Reciprocation of the piston agitates the oil, which causes it to circulate in the annular gallery 256. In response to the agitation and piston motion, oil also flows from the annular gallery 256 into the central gallery 257. Piston reciprocation also agitates the oil collected or accumulated in the central gallery 257 so as to cool the undercrown 208 beneath the central portion of the end surface 206. The oil flows from the bottom of central gallery 257 via one or more passages in the bearing structure into the interior of the skirt 205. From there, the oil flows out the open end of the skirt 205.

(25) In the prior art gallery cooling constructions described in the Applicant's US 2012/0073526 A1, the lubricating oil jets for cooling the undercrown are provided to the piston galleries from nozzles that are separate from, external to, and fixed with respect to, the pistons. In the embodiments to be described, the oil jets are delivered from elements of the pistons themselves and are fed from oil reservoirs in the piston bearings.

Cooling Jet Constructions

(26) With regard to the piston lubrication constructions thus far described, the pressurized oil delivered to a bearing oil reservoir for lubrication may at the same time be used for undercrown cooling in an opposed-piston engine. In some aspects, pressurized oil obtained from a bearing oil reservoir is provided in the form of a high velocity stream or jet for cooling a piston undercrown. Hereinafter such a jet is referred to as a cooling jet, for convenience and clarity. A cooling jet is provided from a cooling jet outlet that is in fluid communication with the bearing oil reservoir. At least one cooling jet constituted of received, pressurized lubricating oil is provided from each piston bearing so as to cool a portion of the undercrown by impingement. Jetted oil flows from the undercrown portion into the piston cooling galleries so as to provide a constant replenishment of coolant with which to cool the rest of the undercrown by irrigation. A cooling jet may be stationary, or it may be swept in an oscillating motion.

(27) FIGS. 4, 5A, and 5B illustrate two cooling jet embodiments. Although both embodiments are shown together in one or more of the figures, this is for convenience and clarity. In fact the embodiments are proposed as alternatives. That is to say a piston may be equipped with one or the other, as required by design considerations and cost.

First Embodiment

(28) Continuing with the exemplary piston construction shown in FIGS. 4 and 5A, a first cooling jet outlet embodiment is constituted of a passage 270 drilled or formed in the bearing support member 219a. One end of the passage 270 is in fluid communication with the oil reservoir 222 via an oiling groove 227. When pressurized oil received in the reservoir enters the oiling grooves 227, a portion of it flows into the passage 270 whence it is emitted in the form of a coolant jet 272. The passage 270 is located and oriented so as to be aimed at the undercrown portion 260. As a result, the coolant jet 272 is directed toward the hot spot in the crown 203 that is associated with the ridge 209. As should be evident with regard to the figures, the bearing support member 219a is fixed to the undercrown. Lacking relative movement between the member 219a and the undercrown 208, the jet 272 is stationary with respect to the undercrown 208.

Second Embodiment

(29) An alternative coolant jet outlet is best seen in FIGS. 4 and 5B, where a nozzle 278 is mounted to the wristpin 221 so as to be in fluid communication with the reservoir 222 by way of an oil outlet 280. In the illustrated example, the oil outlet 280 is formed in the flange 252, and the nozzle 278 is mounted thereto by an elbow joint 281 received in the oil outlet. The nozzle 278 extends into the annular gallery 256, aimed toward the undercrown portion 260. Pressurized oil received in the reservoir 222 flows into the nozzle through the oil outlet 280 and the elbow joint 281. From the nozzle 278, the pressurized oil is emitted in the form of a coolant jet 284. As should be evident with regard to the figures, the wristpin 221 undergoes oscillatory movement relative to the undercrown 208. As a result, the coolant jet 284 is swept to and fro across the undercrown portion 260.

Second Piston Construction

(30) In some aspects, it may be desirable to provide more than one cooling jet to the undercrown of a piston with an end surface construction having a more complex contour than that of the piston of FIG. 2. For example, the first combustion chamber construction for an opposed-piston engine described and illustrated in the Applicant's WO2012/158756 includes a piston end surface with two opposing ridges, each with an associated hot spot. Such a piston is shown in FIG. 6, in which the piston 300 has a crown 303 with an end surface 306 and an undercrown 308. The end surface includes an elongated cleft 307 extending in a diametrical direction of the piston 300, defined between opposing ridges 309. As best seen in FIGS. 7A and 7B, the undercrown 308 includes annular and central cooling galleries and the piston includes a bearing structure identical to that of the bearing 217 of FIG. 4, except that the first and second cooling jet embodiments include two jet outlets each, with each cooling jet outlet aimed at a respective hot spot portion of the undercrown.

Central Gallery Cooling

(31) Referring to FIGS. 3 and 8, in some aspects, it may be desirable to cool the undercrown 208 of the piston 200 by flow of lubricating oil to and through the central gallery 257. In such cases, a cooling jet outlet embodiment is constituted of a passage 275 drilled or formed in the bearing support member 219a. One end of the passage 275 is in fluid communication with the oil reservoir via an oiling groove 227. When pressurized oil received in the reservoir enters the oiling grooves 227, a portion of it flows into the passage 275 whence it is emitted in the form of a coolant jet. The passage 275 is located and oriented so as to be aimed at the central gallery 257. As a result, the coolant jet is directed toward a portion of the crown 203 that is associated with the deepest portion of the bowl 214. Lacking relative movement between the member 219a and the undercrown 208, the jet emitted from the passage is stationary with respect to the undercrown 208. In some aspects it may be desirable to direct more than one coolant jet into the central gallery 257; this is provided by the second passage 275 indicated by the dotted line in FIG. 8. With reference to FIGS. 6 and 7A, it should be evident that the same provisions may be made to the piston 300 so as to enable one or more cooling jest of lubricating oil to be injected into the central cooling gallery of the crown 303, which would delivery of liquid coolant to the part of the undersurface that underlies the deepest portion of the cleft 307.

Method of Operating an Opposed-Piston Engine

(32) With reference to the figures, an opposed-piston engine such as the engine 49 includes at least one cylinder 50 and a pair of pistons 200 equipped with bearing constructions as described herein. The pistons are disposed in opposition to one another in a bore 52 of the cylinder, and each piston is connected to a respective connecting rod 210 by a bearing 217. The engine is operated by a method that includes providing a flow of pressurized oil to each bearing 217. The flow of pressurized oil to each bearing 217 is received in a wristpin 222 of the bearing. In response to pressurized oil in the wristpins, multiple streams of the received, pressurized oil from each wristpin are provided to lubricate a respective bearing interface, and at least one jet of the received, pressurized oil is provided from one of a fixed part and a moving part of each bearing, in which each jet is aimed at a respective piston undercrown portion. In the method, the flow of pressurized oil is received in an oil reservoir in the wristpin. In the method, providing a jet from a moving part of each bearing includes providing the jet from a wristpin. In the method, providing a jet from a moving part of each bearing includes sweeping the jet across the respective piston undercrown portion.

(33) The cooling construction embodiments that are described herein, and the devices and methods with which they are implemented, are illustrative and are not intended to be limiting.