PENDULUM ASSEMBLY FOR A CRANKSHAFT PENDULUM HAVING CAST-IN NEAR NET SHAPE HARDENED INSERTS

Abstract

A pendulum crankshaft for an internal combustion engine includes a pendulum crankshaft having pendulum crank rolling path inserts that are cast into the component during the casting process. The rolling path inserts are positioned in a mold prior to casting. By including the rolling path inserts in the component during the molding process, the need to press the rolling path insert into the component after the component is cast eliminates the resulting stresses that would otherwise result. Machining and subsequent heat treatment are unnecessary. The component can be one or both of the crankshaft pendulum and the pendulum carrier. The rolling path may be formed from a metal such as sintered powdered metal. The flowable material may be a metal such as iron. The resulting component is free of stress regions, such as on the carrier strap, that normally result from methods that involve press-fitting the rolling path insert into the component.

Claims

1. A method of producing a crankshaft pendulum assembly for an internal combustion engine, the method comprising: forming a mold for a crankshaft pendulum assembly component, said component being selected from the group consisting of a pendulum carrier and a crankshaft pendulum movably attached to said carrier; forming a rolling path insert; positioning said rolling path insert in said mold; and injecting flowable material into said mold to form said component.

2. The method of producing a crankshaft pendulum assembly of claim 1, wherein said rolling path insert is formed from a metal selected from the group consisting of sintered powdered metal and hardened steel.

3. The method of producing a crankshaft pendulum assembly claim 1, wherein said flowable material is a molten metal.

4. The method of producing a crankshaft pendulum assembly claim 1, wherein said flowable material is molten iron.

5. The method of producing a crankshaft pendulum assembly of claim 1, wherein each of said components includes a pair of said rolling path inserts.

6. A method of producing a crankshaft pendulum assembly for an internal combustion engine, the method comprising: forming a mold for a crankshaft pendulum assembly component; forming a rolling path insert; positioning said rolling path insert in said mold; and injecting flowable material into said mold to form said component.

7. The method of producing a crankshaft pendulum assembly of claim 6, wherein said crankshaft pendulum assembly component is a crankshaft pendulum.

8. The method of producing a crankshaft pendulum assembly of claim 6, wherein said crankshaft pendulum assembly component is a pendulum carrier.

9. The method of producing a crankshaft pendulum assembly of claim 6, wherein said rolling path insert is formed from a metal selected from the group consisting of sintered powdered metal and hardened steel.

10. The method of producing a crankshaft pendulum assembly claim 6, wherein said flowable material is a molten metal.

11. The method of producing a crankshaft pendulum assembly claim 6, wherein said flowable material is molten iron.

12. The method of producing a crankshaft pendulum assembly of claim 6, wherein each of said components includes a pair of said rolling path inserts.

13. A crankshaft pendulum assembly for attachment to the crankshaft of an internal combustion engine, the assembly comprising: a crankshaft pendulum component formed from a cast material, said component including a body; a rolling path insert positioned substantially within said component, said insert being cast into said component; and a region formed in said body around said rolling path insert, said region being free of induced stress.

14. The crankshaft pendulum assembly of claim 13, wherein said component is a crankshaft pendulum.

15. The crankshaft pendulum assembly of claim 14, wherein said crankshaft pendulum is formed from two halves and wherein each of said halves includes at least one rolling path insert.

16. The crankshaft pendulum assembly of claim 13, wherein said component is a pendulum carrier.

17. The crankshaft pendulum assembly of claim 16, wherein said pendulum carrier includes a carrier strap and wherein said region is formed substantially within said carrier strap.

18. The crankshaft pendulum assembly of claim 13, wherein said rolling path insert is formed from a metal.

19. The crankshaft pendulum assembly of claim 18, wherein said metal from which said rolling path insert is formed is sintered powdered metal.

20. The crankshaft pendulum assembly of claim 13, wherein said cast material is iron.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] For a more complete understanding of this invention, reference should now be made to the embodiments illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein:

[0013] FIG. 1 is a front view of a pendulum carrier and one half of a crankshaft pendulum attached to the pendulum carrier in which the pendulum carrier includes rolling path inserts according to known technology;

[0014] FIG. 2 is a perspective view of a portion of the pendulum carrier of known technology from which the insert has been removed to illustrate the stress in the area adjacent the insert hole that results from placement of the insert into the pendulum carrier ear;

[0015] FIG. 3 is a front view of a cast iron pendulum carrier having machined rolling pathways according to known technology;

[0016] FIG. 4 is a front view of half of a crankshaft pendulum having cast-in near net shape hardened cycloid sleeve inserts according to the disclosed inventive concept;

[0017] FIG. 5 shows a perspective view of the crankshaft pendulum half of FIG. 4;

[0018] FIG. 6 is a perspective view of a portion of the pendulum carrier of the disclosed inventive concept illustrating the cast-in cycloid sleeve insert; and

[0019] FIG. 7 is a plan view of a mold having a mold cavity in which a pair of hardened cycloid sleeve inserts have been placed prior to injection of the molten material.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020] In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for different constructed embodiments. These specific parameters and components are included as examples and are not meant to be limiting.

[0021] As illustrated in FIGS. 1 through 3, two different approaches to forming a rolling pathway in the parts of a crankshaft pendulum assembly according to known technology are illustrated. FIGS. 4 through 6 illustrate components of the crankshaft pendulum assembly according to the disclosed inventive concept in which cast-in cycloid sleeve inserts are provided.

[0022] Referring to FIG. 1, a front view of a crankshaft pendulum and pendulum carrier assembly according to known technology, generally illustrated as 10, is shown. The assembly 10 includes a crankshaft pendulum half 12 movably attached to a pendulum carrier 14. The pendulum carrier 14 is attached to an engine crankshaft (not shown). The crankshaft pendulum half 12 represents one-half of a whole crankshaft pendulum (not shown), the one-half being removed so that the pendulum carrier 14 can be illustrated in relation to the crankshaft pendulum half 12.

[0023] The crankshaft pendulum half 12 includes a centrally-formed raised area 16 and a pair of recessed areas 18 and 18 formed laterally of the centrally-formed raised area 16. A pair of fastener holes 20 and 20 are formed in the centrally-formed raised area 16 for fasteners (not shown) that are used to fix the two halves of the crankshaft pendulum together.

[0024] Each of the crankshaft pendulum half 12 and the pendulum carrier 14 have rolling pathways formed therein. Specifically, the crankshaft pendulum half 12 includes a first pendulum rolling pathway 22 and a second pendulum rolling pathway 22. The pendulum carrier 14 includes a first pendulum carrier rolling pathway 24 and a second pendulum carrier rolling pathway 24. A pendulum roller 26 is positioned within both the first pendulum rolling pathway 22 and the first pendulum carrier rolling pathway 24. A pendulum roller 26 is positioned within both the first pendulum rolling pathway 22 and the first pendulum carrier rolling pathway 24. As illustrated in FIG. 1, the crankshaft pendulum half 12 is in its full out position relative to the pendulum carrier 14.

[0025] The pendulum carrier 14 includes a body 27 having carrier ears 28 and 28. The carrier ear 28 includes a carrier strap 29 and the carrier ear 28 includes a carrier strap 29. The body 27 is attached to the crankshaft (not shown).

[0026] The carrier ear 28 includes an insert hole 30 formed by the carrier strap 29 and the carrier ear 28 includes an insert hole 30 formed by the carrier strap 29. A carrier insert 32 is press-fitted into the insert hole 30 of the carrier ear 28. A carrier insert 32 is press-fitted into the insert hole 30 of the carrier ear 28. The press-fitted carrier inserts 32 and 32 may be made from a hardened metal, such as hardened powder metal or hardened steel. A pin 34 is provided to aid in the orientation of the pressed-in carrier insert 32 relative to the carrier ear 28 during assembly. In the same manner, a pin 34 is provided to aid in the orientation of the pressed-in carrier insert 32 relative to the carrier ear 28 during assembly.

[0027] According to known crankshaft pendulum construction, the pressed-in carrier insert is press-fitted into the pendulum carrier by a press suitable for such a purpose. Because the fit between the pressed-in carrier insert and the carrier ear is typically an interference fit, insertion of the carrier insert into the insert hole results in undesirable stress on the area of the carrier ear adjacent to the insert hole. This situation is illustrated in FIG. 2, in which a perspective view of a portion of the pendulum carrier 14 of FIG. 1 is shown. Particularly, the carrier ear 28 is shown without the pressed-in carrier insert in place to illustrate the stress created in the area adjacent the insert hole 30 after the carrier insert is installed.

[0028] Referring to FIG. 2, the installation of the carrier insert by press-fitting can generate a Von Mises stress in the carrier strap 29 of more than 3000 MPa. The distribution of Von Mises stress is illustrated in FIG. 2 in which the areas designated as 34 undergo the greatest level of stress of over 450 MPa, while the area designated as 36 undergo the second greatest level of stress of over 400 MPa. As illustrated, the greatest concentration of stress is in the thinnest area of the carrier strap 29, whereas the lowest level of stress is an area 38 that defines the neck connecting the carrier strap 29 to the body 27 of the pendulum carrier 14. The illustrated Von Mises stress on the carrier strap 29 that results upon insertion of the pressed-in carrier insert is an undesirable result of known assembly techniques.

[0029] In an effort to eliminate the stresses created in the carrier strap by known approaches, cycloids have been machined directly in cast iron pendulums and pendulum carriers. According to this approach, no insert is required, and thus stresses to the local environment are avoided. An example of a component of the crankshaft pendulum carrier assembly that is cast and machined is illustrated in FIG. 3 in which a front view of a cast pendulum carrier 40 is illustrated. The cast pendulum 40, typically made from cast iron, includes carrier ears 42 and 42 attached to a carrier body 44. A rolling path 46 is machined directly into the carrier ear 42 and a rolling path 46 is machined directly into the carrier ear 42. Rolling pins (not shown) are movably fitted within the rolling paths 46 and 46.

[0030] In operation, the rolling paths 46 and 46 of the cast pendulum carrier 40 yield at the rolling pin contact. To prevent this undesirable result, heat treatment of the cast iron component is required following machining. The step of heat treatment, added to the expense of machining, renders this approach to providing a solution to the problem of costly crankshaft pendulum assembly components impractical. But the added step of heat treatment may not provide satisfactory results, in that the cast iron (even austempered ductile iron [ADI], a heat treated cast iron) often experience unacceptable wear. Thus a forged or stamped steel design that is hardened is required. However, the hardening process itself causes distortion in the steel and subsequent hard machining.

[0031] The disclosed inventive concept avoids known inadequacies in methods and material by providing an alternative to known approaches to constructing a crankshaft pendulum assembly. Particularly, and referring to FIGS. 4 through 6, components of a crankshaft pendulum assembly incorporating cast-in cycloid sleeve inserts are illustrated.

[0032] FIG. 4 illustrates a front view of a portion of a crankshaft pendulum half 50 constructed according to the disclosed inventive concept is illustrated. FIG. 5 illustrates a perspective view of the crankshaft pendulum half 50. Referring to both FIG. 4 and FIG. 5, the crankshaft pendulum half 50 is attached to a pendulum carrier (not shown) which is itself attached to the crankshaft. The crankshaft pendulum half 50 represents one-half of a whole crankshaft pendulum (not shown). The covering half is removed for purposes of illustration.

[0033] The crankshaft pendulum half 50 includes a centrally-formed raised area 52 and a pair of recessed areas 54 and 54 formed laterally of the centrally-formed raised area 52. A pair of fastener holes 56 and 56 are formed in the centrally-formed raised area 52 for fasteners (not shown) that are used to fix the two halves of the crankshaft pendulum together.

[0034] The crankshaft pendulum half 50 includes cast-in, near net shape hardened rolling path insert sleeves 60 and 60. The rolling path insert sleeves 60 and 60 are preferably formed from a powdered or sintered metal, although other materials such as hardened steel may be suitable.

[0035] The crankshaft pendulum halves are not the only components of the crankshaft pendulum assembly that can be formed with rolling path insert sleeves. In addition or in the alternative, the pendulum carrier may also be formed with rolling path insert sleeves, as illustrated in FIG. 6. With reference to that figure, a perspective view of a portion of a pendulum carrier 62 is illustrated. The pendulum carrier 62 includes a pendulum carrier ear 64 that is attached to a pendulum carrier body 66. A cast-in, near net shape hardened rolling path insert sleeve 68 is provided. Like the rolling path insert sleeves 60 and 60, the rolling path insert sleeve 68 is preferably formed from sintered powdered metal, although other materials may be suitable.

[0036] To manufacture either the crankshaft pendulum or the pendulum carrier, the cycloid sleeves are first positioned within the appropriate mold. An example of the positions of the cycloid sleeves within a mold is shown in FIG. 7 in which a mold 70 for a crankshaft pendulum half is shown. The mold 70 includes a mold body 72 having a mold cavity 74 defined therein. Once formed, the rolling path insert sleeves 60 and 60 (or the rolling path insert sleeve 68 in the case of a pendulum carrier) are positioned within the mold 70 prior to injection. Once correctly positioned, the mold is closed and the flowable material, such as cast iron, is injected into the mold 70.

[0037] Use of the cast-in, near net shape hardened rolling path insert sleeve in either or both of the crankshaft pendulum and the pendulum carrier according to the disclosed inventive concept avoids the stresses caused by press fitting as is known to result from assembly based on known technology. In addition, use of the cast-in, near net shape hardened rolling path insert sleeve in either or both of the crankshaft pendulum and the pendulum carrier according to the disclosed inventive concept avoids the added cost associated with the need to machine and heat treat a cast metal part. The disclosed inventive concept provides the benefit of a hardened near net shape rolling path insert while eliminating the disadvantages attendant the known technologies.

[0038] In addition to providing the specified advantages over known approaches to forming a rolling path insert in crankshaft pendulum assemblies, one skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims that various changes, modifications and variations can be made therein without departing from the true spirit and fair scope of the invention as defined by the following claims.