Variable compression ratio engine
10184394 ยท 2019-01-22
Inventors
Cpc classification
F16J3/042
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F02D15/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16J15/52
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F02B75/04
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
According to the present invention a variable compression ratio engine having a pair of eccentric control shafts, a crankcase and a cylinder jug has contiguous metal casting bearing sockets located in the crankcase for supporting the eccentric control shaft, and an eccentric control shaft axis location close in to the working cylinders, and located between the bottom edge of the working cylinders and the floor of the water jacket, thereby providing a rigid and compact crankcase and cylinder jug assembly. Nesting of the eccentric control shafts under the water jacket and close in to the cylinder bores, and also eliminating use of removable bearing caps in the crankcase provides a compact and rigid crankcase and cylinder jug assembly. Side walls that extend above and below the eccentric control shafts provide added rigidity and also enclose the crankcase for containing oil within the crankcase. Internal webbing within the crankcase provides added rigidity and provides an aerodynamic crankcase interior and an oil drain back passageway for reduced internal aerodynamic drag on the cranktrain at high engine speeds. A major benefit of the present invention is that it is robust and can support the large forces encountered in internal combustion engines. Another benefit of the present invention is that removable bearing caps are not required, resulting in a lower cost and a smaller size than prior art engines having removable bearing caps.
Claims
1. A rigid variable compression ratio crankcase (2) and cylinder jug (4) assembly for a variable compression ratio engine (6), said variable compression ratio engine (6) having a crankshaft (8) and at least one piston (12) and at least one connecting rod (14), said variable compression ratio engine (6) having a maximum compression ratio setting (38) and a minimum compression ratio setting (36), said crankcase (2) further having a contiguous metal casting forming at least a first and a second bulkhead (18 and 20), said first bulkhead (18) having two crankcase bearing sockets (22a), said crankcase bearing sockets (22a) passing through said contiguous metal casting and being centered generally on a common first bulkhead plane (B), and, said second bulkhead (20) having two crankcase bearing sockets (22b), said crankcase bearing sockets (22b) passing through said contiguous metal casting and being centered generally on a common second bulkhead plane (C), said crankcase (2) further having two eccentric control shafts (24 and 26), at least a portion of said control shafts being free to axially slide into said variable compression ratio engine (6) for assembly of said variable compression ratio mechanism, and said cylinder jug (4) further having a deck (28) for mounting of a cylinder head, and a cylinder bore (16) for receiving said piston (12), said cylinder bore (16) having a cylinder bottom edge (30), a cylinder bore diameter (D), and a cylinder bore cross sectional area (34), wherein, said first eccentric control shaft (24) has a first axis (40) located in said crankcase (2), and said second eccentric control shaft (26) has a second axis (42) located in said crankcase (2), said first axis (40) and said second axis (42) further defining a common control shaft plane (E) in said crankcase (2), said common control shaft plane (E) being located between said deck (28) and said bottom edge (30), and, said crankcase (2) having rigid side walls (44) between said bulkheads (18 and 20) and extending above and below said common control shaft plane (E) for enclosing said crankcase (2) and for providing axial stiffness of said crankcase between said bulkheads (18 and 20), said first bulkhead (18) having said rigid side walls (44) further includes a deep inner saddle (46) between said crankcase bearing sockets (22) and passing through said common control shaft plane (E) for installation of said cylinder jug (4), wherein said crankcase has bearing sockets (22) for two eccentric control shafts (24 and 26); rigid side walls (44) extending above and below said common control shaft plane (E); contiguous metal casting around said crankcase bearing sockets (22); and said deep inner saddle (46) passing through said common plane (E) for installation of said cylinder jug (4), thereby providing a narrow and rigid variable compression ratio crankcase.
2. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, further including a water jacket (68), and a water jacket depth reference plane (W), water jacket depth reference plane (W) being parallel to deck plane (F), the space between deck plane (F) and water jacket depth reference plane (W) being equal to bore diameter (D), wherein, common control shaft plane E is located between water jacket reference plane W and cylinder bottom edge 30 for closely nesting the eccentric control shafts (24 and 26) under water jacket (68) and close to cylinder bore (16).
3. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said deep inner saddle (46) has a saddle opening width (48), said saddle opening width (48) being measured on said common control shaft plane (E), wherein said saddle opening width (48) is no more than 1.12 times said cylinder bore diameter (D).
4. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said crankcase bearing sockets (22) have an inner cross sectional area (50) measured on said common control shaft plane (E), wherein said inner cross sectional area (50) is at least eight percent of said cylinder bore cross sectional area (34), thereby providing robust bearing support structure.
5. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said crankshaft (8) defines a crankshaft rotational axis (10), and a crankshaft horizontal plane (G) passing through said crankshaft rotational axis (10) and being parallel to said common control shaft plane (E), said crankcase (2) further including cross webbing (52) between said first bulkhead (18) and said second bulkhead (20), said cross webbing (52) being located generally between said common control shaft plane (E) and said crankshaft horizontal plane (G), thereby providing a rigid and internally aerodynamic crankcase.
6. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 5, wherein said cross webbing (52) and said rigid side wall (44) forms an oil drain back passageway (54), thereby directing engine oil away from the spinning crankshaft (8) for minimizing aerodynamic losses and maximizing engine efficiency and power.
7. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 2, wherein, cylinder jug (4) further has a contiguous metal casting (62) forming at least a first cylinder jug bearing housing (56) having a cylinder jug bearing surface (58), and a second cylinder jug bearing housing (60) having a cylinder jug bearing socket surface (58), first cylinder jug bearing housing (56) and second cylinder jug bearing housing (60) being located generally on a cylinder bore plane (A) located between first bulkhead plane (B) and second bulkhead plane (C), wherein, first cylinder jug bearing housing (56) has a contiguous metal casting (62) encircling jug bearing socket surface (58), thereby providing a narrow and rigid cylinder jug.
8. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 7, wherein said cylinder jug bearing housings (56 and 60) have an outer cross sectional area (66) measured on said common control shaft plane (E), wherein said outer cross sectional area (66) is at least eight percent of said cylinder bore cross sectional area (34), thereby providing robust bearing support structure.
9. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 7, wherein said cylinder jug bearing surfaces (58) define a common bearing lower plane (H), said common bearing lower plane (H) being parallel to said common control shaft plane (E), said common bearing lower plane (H) being located between said water jacket reference plane (W) and said bottom edge (30), thereby providing a rigid cylinder jug bearing housing.
10. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 7, wherein said cylinder jug (4) further includes a water Jacket (68), said water jacket (68) and said cylinder jug bearing housing (56) having a common lower wall section (70) located on said common cylinder bore plane (A), said lower water jacket section (70) being located between said common control shaft plane (E) and said deck (28), thereby providing a narrow cylinder jug having a deep water jacket.
11. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said cylinder jug (4) further includes structural webbing (72) extending from said cylinder jug bearing housing (56) to said deck (28), thereby providing a rigid cylinder jug structure.
12. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 11, wherein said cylinder jug (4) further includes cylinder head bolt anchorages (74), wherein said structural webbing (72) extends generally from said cylinder jug bearing housing (56) towards said cylinder head bolt anchorages (74), thereby providing a rigid cylinder jug structure.
13. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 12, wherein at least one cylinder jug bearing housing (56) includes a first webbing (72a) extending generally towards a cylinder head bolt anchorage (74) located in said first bulkhead (18), and a second webbing (72b) extending generally towards a cylinder head bolt anchorage (74) located in said second bulkhead (20), thereby providing a rigid cylinder jug structure.
14. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said cylinder jug (4) has deep sockets (76) between adjacent cylinder jug bearing housings (56) and common control shaft plane (E) for providing mechanical clearance from the contiguous metal castings (18) around the crankcase bearing sockets (22).
15. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 14, wherein said cylinder jug (4) has a maximum fitting width (78) for installation of said cylinder jug (4) in said saddle opening width (48) without mechanical interference, said maximum fitting width (78) being measured on said common control shaft plane (E) and on said common first bulkhead plane (B) between said deep sockets (76), wherein said maximum fitting width (78) is no more than ninety percent of said cylinder bore diameter (D).
16. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 15, wherein said deep inner saddle (46) has a saddle opening width (48), said saddle opening width being measured on said common control shaft plane (E), wherein said saddle opening width (48) is no more than 1.12 times said cylinder bore diameter (D).
17. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 14, wherein said cylinder jug (4) further includes cylinder head bolt anchorages (74), wherein said cylinder head bolt anchorages (74) are through drilled into said deep sockets (76).
18. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, further having crankshaft bearings (80), a crankshaft lower bearing housing (82) and main fasteners (84) for securing said lower bearing housing (82) to said crankcase (2), and said crankcase (2) further has an oil feed line (86) for supplying oil to said crankshaft bearings (80), wherein said oil feed line (86) crosses at least one main fastener (84) for oil flow around said main fastener (84) to said crankshaft bearing (80).
19. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said cylinder jug (4) further includes a water Jacket (68), and said deck (28) further including a rear bib (88), wherein said rear bib (88) includes a water inlet passage (90) for feeding cooling water into said water jacket (68) from above said deck (28).
20. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said crankcase (2) and cylinder jug (4) assembly further including a thrust bearing (96) thrust bearing (96) being located between a cylinder jug bearing housing (56) and a crankcase bulkhead (20), thereby providing precision alignment of said cylinder jug in said crankcase.
21. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, further including an eccentric bushing (100) mounted in said crankcase (2) and a locking fastener (102) for locking said eccentric bushing (100) in place in said crankcase (2).
22. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, wherein said crankcase (2) further has external ribbing (104) located on the outer surface of said side walls (44).
23. The rigid variable compression ratio crankcase and cylinder jug assembly of claim 1, further having an end crankcase bearing socket (106) and a rear cover plate (108) for sealing said end bearing socket (106), said eccentric control shaft (24) further having an internal oil galley (110) for supplying oil to said crankcase bearing sockets (22), and said crankcase (2) further having an oil feed galley (114) for supplying oil to said end crankcase bearing socket (106) for feeding oil into said internal oil galley (110).
Description
BRIEF DESCRIPTION OF THE FIGURES
(1)
(2)
(3)
(4)
(5)
(6)
(7)
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
(8)
(9) Cylinder jug 4 has a cylinder bore plane A. Cylinder bore plane A passes through the center of cylinder bore 16 and is perpendicular to crankshaft axis 10.
(10) Crankcase 2 has a contiguous metal casting forming at least a first bulkhead 18 and a second bulkhead 20. First bulkhead 18 has two crankcase bearing sockets 22a, or more generally crankcase bearing sockets 22. Crankcase bearing sockets 22a pass through contiguous metal casting 18 and are centered generally on a common first bulkhead plane B.
(11) Second bulkhead 20 has two crankcase bearing sockets 22b. Crankcase bearing sockets 22b pass through contiguous metal casting 20 and are centered generally on a common second bulkhead plane C.
(12) Variable compression ratio crankcase 2 further has a first eccentric control shaft 24 and a second eccentric control shaft 26. Preferably at least a portion of control shafts 24 and 26 are free to axially slide into crankcase bearing sockets 22 having contiguous metal casting 18 and into in variable compression ratio engine 6 for assembly of the variable compression ratio mechanism.
(13) Cylinder jug 4 further has a deck 28 for mounting of a cylinder head. Deck 28 defines a deck plane F. Referring now to
(14) Referring now to
(15) Referring now to
(16) Crankcase 2 has rigid side walls 44. The rigid side walls 44 are located between first bulkhead 18 and second bulkhead 20, and extending above and below common control shaft plan E for enclosing the crankcase 2 and for providing axial stiffness of crankcase 2 between the bulkheads.
(17) Referring now to
(18) According to the present invention crankcase 2 has a common control shaft plane E located at a mid-bore height between deck plane F and cylinder bottom edge 30; control shaft bearing sockets 22 centered on common control shaft plane E; contiguous metal casting around crankcase bearing sockets 22 in bulkheads 18 and 20 to provide rigid support of the bearings; rigid side walls 44 extending above and below common control shaft plane E for further strengthening bulkheads 18 and 20; and a deep inner saddle 46 passing through common plane E for installation of cylinder jug 4 in variable compression ratio engine 6, thereby providing a narrow and rigid variable compression ratio crankcase.
(19) Referring now to
(20) According to the preferred embodiment of the present invention crankcase 2 has a common control shaft plane E located between water jacket reference plane W and cylinder bottom edge 30; control shaft bearing sockets 22 centered on common control shaft plane E; contiguous metal casting around crankcase bearing sockets 22 in bulkheads 18 and 20 to provide rigid support of the bearings; rigid side walls 44 extending above and below common control shaft plane E for further strengthening bulkheads 18 and 20; and a deep inner saddle 46 passing through common plane E for installation of cylinder jug 4 in variable compression ratio engine 6, thereby providing a narrow and rigid variable compression ratio crankcase. In general, eccentric control shafts 24 and 26 are nested under water jacket 68 for minimizing the bridging distance between the two shafts for maximizing crankcase rigidity and minimizing engine width.
(21) In more detail, according to the present invention variable compression ratio engine 6 has a pair of eccentric control shafts 24 and 26, a crankcase 2 and a cylinder jug 4 having contiguous metal casting bearing sockets 22 located in the crankcase 2 for supporting the eccentric control shaft 24 and 26, and an eccentric control shaft axis location 40 and 42 close in to the working cylinders 16, and located between the bottom edge 30 of the working cylinders 16 water jacket reference plane W, thereby providing a rigid and compact crankcase 2 and cylinder jug 4 assembly. Nesting of the eccentric control shafts 24 and 26 under the water jacket 68 and close in to the cylinder bores 16, and also eliminating use of removable bearing caps in the crankcase, provides a compact and rigid crankcase 2 and cylinder jug 4 assembly.
(22) Referring now to
(23) Referring now to
(24) Referring now to
(25) Preferably, according to the present invention, cross webbing 52 and rigid side walls 44 form an oil drain back passageway 54 for directing engine oil away from the spinning crankshaft 8 for minimizing aerodynamic losses and maximizing engine efficiency and power. Drain back passageway 54 provides for an open passageway between first bulkhead B and second bulkhead C and between common control shaft plan E to below crankshaft horizontal plane G for drainage of engine oil.
(26) Referring now to
(27) Bearing socket surface 58 defines a bearing socket axis 64. Preferably, according to the present invention, cylinder jug bearing housings 56 and 60 have an outer cross sectional area 66. The cross hatching has been removed from outer cross sectional area 66 where shown by the leader line in
(28) Referring now to
(29) Referring now to
(30) Referring now to
(31) Referring now to
(32) Referring now to
(33) Preferably deep inner saddle 46 has a saddle opening width 48, saddle opening width being measured on common control shaft plane E when bearing socket axis 64 is located on common control shaft plane E, and the saddle opening width 48 is no more than 1.12 times cylinder bore diameter D. Preferably cylinder jug 4 having cylinder head bolt anchorages 74 that are through drilled into deep sockets 76.
(34) Referring now to
(35) Preferably, according to the present invention, an oil feed line 86 and at least one main fastener 84 are generally centered in first bulkhead plane B, and oil feed line 86 crosses main fastener 84 for oil flow around main fastener 84 to crankshaft bearing 80.
(36) Preferably main fasteners 84 have a narrower shank or a relief for a larger oil flow passageway around fastener 84, and in more detail the diameter of the fastener shank is preferably smaller than the outer diameter of the fastener thread where oil feed line 86 crosses main fastener 84.
(37) Referring now to
(38) Preferably crankcase 2 has a crankcase pocket wall 92 for enclosing bib 88 inside crankcase 2. Crankcase pocket wall 92 optionally extends over a bellhousing flange 94, thereby providing a cooling water inlet without significantly increasing the overall length of variable compression ratio engine 6. Water outlet passageways are typically provided in the cylinder head. An inlet water passageway may optionally be provided in the cylinder head for feeding water into water inlet passageway 90. An engine knock sensor may also be accessed through bib 88 or a secondary bib.
(39) Referring now to
(40) Referring now to
(41) Preferably crankcase 2 further has external ribbing 104 located on the outer surface of side walls 44 for providing a stiffer crankcase.
(42) Referring now to
(43) Referring now to