U.S. patent application number 14/472151 was filed with the patent office on 2016-03-03 for rotary device including a counterbalanced seal assembly.
The applicant listed for this patent is GoTek Energy, Inc.. Invention is credited to Bradley Scott Farrenkopf, Steven Lee Herbruck.
Application Number | 20160061039 14/472151 |
Document ID | / |
Family ID | 55400543 |
Filed Date | 2016-03-03 |
United States Patent
Application |
20160061039 |
Kind Code |
A1 |
Herbruck; Steven Lee ; et
al. |
March 3, 2016 |
ROTARY DEVICE INCLUDING A COUNTERBALANCED SEAL ASSEMBLY
Abstract
A rotary device is provided. The rotary device includes a
housing having an inner surface and a rotor assembly mounted for
rotation in the housing about an axis defining an axial direction
of the rotary device. The rotor assembly includes a rotor and a
seal assembly. The rotor includes a central portion and a plurality
of arms extending radially outward from the central portion. Each
arm has a distal end disposed for sliding engagement with the inner
surface, and at least one of the arms has a channel defined
therein. The seal assembly is disposed within the channel, and
includes a seal, a base defining a seal channel configured to
receive the seal, and a counterweight mechanism pivotally coupled
to the base. The counterweight mechanism is configured to control a
contact pressure exerted by the seal on the inner surface resulting
from rotation of the rotor.
Inventors: |
Herbruck; Steven Lee; (Ojai,
CA) ; Farrenkopf; Bradley Scott; (Moorpark,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GoTek Energy, Inc. |
Oak View |
CA |
US |
|
|
Family ID: |
55400543 |
Appl. No.: |
14/472151 |
Filed: |
August 28, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14472048 |
Aug 28, 2014 |
|
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14472151 |
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Current U.S.
Class: |
418/142 |
Current CPC
Class: |
F01C 21/0827 20130101;
F01C 21/008 20130101; F04C 19/005 20130101; F01C 19/04 20130101;
F01C 1/324 20130101 |
International
Class: |
F01C 19/04 20060101
F01C019/04; F01C 21/00 20060101 F01C021/00; F01C 21/08 20060101
F01C021/08; F04C 29/00 20060101 F04C029/00; F04C 15/00 20060101
F04C015/00; F04C 18/34 20060101 F04C018/34; F04C 27/00 20060101
F04C027/00; F01C 1/34 20060101 F01C001/34; F04C 2/34 20060101
F04C002/34 |
Claims
1. A rotary device comprising: a housing having an inner surface;
and a rotor assembly mounted for rotation in said housing about an
axis defining an axial direction of said rotary device, said rotor
assembly comprising: a rotor comprising a central portion and a
plurality of arms extending radially outward from said central
portion, each arm having a distal end disposed for sliding
engagement with said inner surface, at least one of said arms
having a channel defined therein; and a seal assembly disposed
within the channel, said seal assembly comprising: a seal; a base
defining a seal channel configured to receive said seal; and a
counterweight mechanism pivotally coupled to said base, said
counterweight mechanism configured to control a contact pressure
exerted by said seal on said inner surface resulting from rotation
of said rotor.
2. A rotary device in accordance with claim 1, wherein said seal
assembly is configured to slide in the axial direction within the
channel defined in said at least one arm.
3. A rotary device in accordance with claim 1, wherein said seal is
configured to slide independently of said base in the axial
direction.
4. A rotary device in accordance with claim 1, wherein said seal
comprises a lip, said lip slidably received between said
counterweight mechanism and said base, said counterweight mechanism
engaging said lip to control the contact pressure exerted by said
seal on said inner surface.
5. A rotary device in accordance with claim 1, wherein said base
comprises a fulcrum defining a pivot axis about which said
counterweight mechanism pivots, the pivot axis substantially
perpendicular to the axial direction.
6. A rotary device in accordance with claim 1, further comprising a
pin hingedly coupling said counterweight mechanism to said
seal.
7. A rotary device in accordance with claim 1, wherein said base
comprises a fulcrum defining a pivot axis about which said
counterweight mechanism pivots, the pivot axis substantially
parallel to the axial direction.
8. A rotary device in accordance with claim 1, wherein said seal
includes a first end and a second end distal from said first end,
each of said first end and said second end having an end groove
defined therein, said seal assembly further comprising a pair of
end seals, each end seal disposed within one of the end
grooves.
9. A rotary device in accordance with claim 1, wherein said rotor
assembly further comprises at least one rocker pivotally coupled to
said rotor for pivoting between a first position spaced from said
inner surface of said housing and a second position adjacent said
inner surface of said housing, wherein pivoting of said rocker
causes said rotor to rotate.
10. A seal assembly for use in a rotary device including a rotor,
said seal assembly comprising: a seal; a base defining a seal
channel extending in a longitudinal direction, said seal disposed
within the seal channel; and a counterweight mechanism pivotally
coupled to said base, said counterweight mechanism configured to
control radial displacement of said seal resulting from centrifugal
forces imparted on said seal by rotation of the rotor.
11. A seal assembly in accordance with claim 10, wherein said seal
is configured to slide independently of said base in the
longitudinal direction.
12. A seal assembly in accordance with claim 10, wherein said seal
comprises a lip slidably received between said counterweight
mechanism and said base, said counterweight mechanism engaging said
lip to control radial displacement of said seal.
13. A seal assembly in accordance with claim 10, wherein said base
comprises a fulcrum defining a pivot axis about which said
counterweight mechanism pivots, the pivot axis substantially
perpendicular to the longitudinal direction.
14. A seal assembly in accordance with claim 10, further comprising
a pin hingedly coupling said counterweight mechanism to said
seal.
15. A seal assembly in accordance with claim 10, wherein said base
comprises a fulcrum defining a pivot axis about which said
counterweight mechanism pivots, the pivot axis substantially
parallel to the longitudinal direction.
16. A seal assembly in accordance with claim 10, wherein said seal
assembly is configured to be slidably received within a seal
assembly channel defined within one of the arms of the rotor.
17. A seal assembly in accordance with claim 10, wherein said seal
includes a first end and a second end distal from said first end,
each of said first end and said second end having an end groove
defined therein, said seal assembly further comprising a pair of
end seals, each end seal disposed within one of the end
grooves.
18. A rotary device comprising: a housing having an inner surface;
and a rotor assembly mounted for rotation in said housing about an
axis defining an axial direction of said rotary device, said rotor
assembly comprising: a rotor comprising a central portion and a
plurality of arms extending radially outward from said central
portion, each arm having a distal end disposed for sliding
engagement with said inner surface, at least one of said arms
having a channel defined therein; and a seal assembly disposed
within the channel, said seal assembly comprising: a seal; a base
defining a seal channel, said seal disposed within the seal
channel, said base comprising a fulcrum; and a counterweight
mechanism operatively coupled to said fulcrum, said counterweight
mechanism comprising a counterweight and a lever extending away
from said counterweight, wherein rotation of said rotor causes said
counterweight mechanism to pivot about said fulcrum and causes said
lever to exert a radial inward force on said seal.
19. A rotary device in accordance with claim 18, wherein said
fulcrum defines a pivot axis about which said counterweight
mechanism pivots, the pivot axis substantially perpendicular to the
axial direction.
20. A rotary device in accordance with claim 18, wherein said seal
comprises a body and a lip extending outward from said body,
wherein rotation of said rotor causes said lever to exert a radial
inward force on said lip.
21. A rotary device in accordance with claim 18, further comprising
a pin hingedly coupling said counterweight mechanism to said
seal.
22. A rotary device in accordance with claim 18, wherein said
fulcrum defines a pivot axis about which said counterweight
mechanism pivots, the pivot axis substantially parallel to the
axial direction.
23. A rotary device in accordance with claim 18, wherein said rotor
assembly further comprises at least one rocker pivotally coupled to
said rotor for pivoting between a first position spaced from said
inner surface of said housing and a second position adjacent said
inner surface of said housing, wherein pivoting of said rocker
causes said rotor to rotate.
24. A seal assembly for use in a rotary device including a rotor,
said seal assembly comprising: a seal; a base defining a seal
channel, said seal disposed within the seal channel, said base
comprising a fulcrum; and a counterweight mechanism operatively
coupled to said fulcrum, said counterweight mechanism comprising a
counterweight and a lever extending away from said counterweight,
wherein rotation of said rotor causes said counterweight mechanism
to pivot about said fulcrum and causes said lever to exert a radial
inward force on said seal.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 14/472,048, filed Aug. 28, 2014, which is
hereby incorporated by reference in its entirety.
BACKGROUND
[0002] The field of the disclosure relates generally to rotary
devices, and more particularly, to crossover seals used in such
devices.
[0003] Rotary devices, such as internal combustion rotary engines,
generally include a housing and a rotor positioned within the
housing for rotation. The rotor separates the housing into one or
more chambers in which fluids, such as gases or liquids, are
received, compressed, combusted, and/or expelled. In rotary
engines, combustion of compressed air-fuel mixtures within such
chambers causes a rapid expansion of gas, which causes the rotor to
rotate. Rotation of the rotor can be used to power various devices,
such as vehicles, compressors, pumps, and other devices.
[0004] Rotors within such rotary devices typically include seals,
commonly referred to as apex or crossover seals, disposed at a
distally outward portion of the rotor. Apex seals are designed to
form a seal with the housing of the rotary device to seal adjacent
chambers from one another to prevent leakage of gas from one
chamber to another. Some rotary devices also use springs to bias
the apex seals against the housing to ensure sufficient contact
pressure between the seal and the housing to maintain a seal
between adjacent chambers.
[0005] Rotation of the rotor imparts centrifugal forces on apex
seals, which increases the contact pressure between the seals and
the housing as the rotational speed of the rotor increases. When
operated at relatively high rotational speeds, centrifugal forces
acting on the apex seals can result in rapid wear of the seals,
particularly where springs are used to bias the seals against the
housing. Such wear results in an undesirable decrease in the
service life of apex seals.
[0006] Some known rotary devices have omitted springs, and rely on
centrifugal forces to force the apex seals against the housing.
However, operation of such devices at relatively low rotational
speeds has not been adequate because of insufficient sealing
between adjacent chambers.
BRIEF DESCRIPTION
[0007] In one aspect, a rotary device is provided. The rotary
device includes a housing having a cylindrical inner surface and a
rotor assembly mounted for rotation in the housing. The rotor
assembly includes a rotor, at least one rocker pivotally coupled to
the rotor, and a counterbalanced seal assembly. The rotor includes
a central portion and a plurality of arms extending radially
outward from the central portion. Each arm has a distal end
disposed for sliding engagement with the inner surface. The rocker
pivots between a first position spaced from the inner surface of
the housing and a second position adjacent the inner surface of the
housing. Pivoting of the rocker causes the rotor to rotate. The
counterbalanced seal assembly is disposed at the distal end of at
least of one of the arms, and includes a seal and a counterweight
mechanism. The counterweight mechanism is configured to control a
contact pressure exerted by the seal on the inner surface resulting
from rotation of the rotor.
[0008] In another aspect, a rotor assembly for use in a rotary
device is provided. The rotor assembly includes a rotor, at least
one rocker pivotally coupled to the rotor, and a counterbalanced
seal assembly. The rotor includes a central portion and a plurality
of arms extending radially outward from the central portion. The
central portion and the plurality of arms define a plurality of
chambers extending radially outward from the central portion. The
rocker pivots between a first position proximate the central
portion and a second position distal from the central position.
Pivoting of the rocker causes the rotor to rotate. The
counterbalanced seal assembly is configured to inhibit fluid flow
between adjacent chambers of the plurality of chambers. The
counterbalanced seal assembly includes a seal and a counterweight
mechanism configured to control radial displacement of the seal
resulting from centrifugal forces imparted on the seal by rotation
of the rotor.
[0009] In yet another aspect, a rotary device is provided. The
rotary device includes a housing having an inner surface and a
rotor assembly mounted for rotation in the housing. The rotor
assembly includes a rotor, at least one rocker pivotally coupled to
the rotor, and a seal assembly. The rotor includes a central
portion and a plurality of arms extending radially outward from the
central portion. Each arm has a distal end disposed for sliding
engagement with the inner surface. The rocker pivots between a
first position spaced from the inner surface of the housing and a
second position adjacent the inner surface of the housing. Pivoting
of the rocker causes the rotor to rotate. The seal assembly is
disposed at the distal end of at least of one of the arms, and
includes a seal and a control mechanism operably coupled to the
seal. The control mechanism is configured to exert a variable
radial force on the seal to control a contact pressure exerted by
the seal on the inner surface resulting from rotation of the
rotor.
[0010] In yet another aspect, a rotary device is provided. The
rotary device includes a housing having an inner surface, and a
rotor assembly mounted for rotation in the housing about an axis
defining an axial direction of the rotary device. The rotor
assembly includes a rotor and a seal assembly. The rotor includes a
central portion and a plurality of arms extending radially outward
from the central portion. Each arm has a distal end disposed for
sliding engagement with the inner surface of the housing, and at
least one of the arms has a channel defined therein. The seal
assembly is disposed within the channel. The seal assembly includes
a seal, a base defining a seal channel configured to receive the
seal, and a counterweight mechanism. The counterweight mechanism is
pivotally coupled to the base, and is configured to control a
contact pressure exerted by the seal on the inner surface of the
housing resulting from rotation of the rotor.
[0011] In yet another aspect, a seal assembly for use in a rotary
device including a rotor is provided. The seal assembly includes a
seal, a base, and a counterweight mechanism. The base defines a
seal channel extending in a longitudinal direction. The seal is
disposed within the seal channel. The counterweight mechanism is
pivotally coupled to the base, and is configured to control radial
displacement of the seal resulting from centrifugal forces imparted
on the seal by rotation of the rotor.
[0012] In yet another aspect, a rotary device is provided. The
rotary device includes a housing having an inner surface and a
rotor assembly mounted for rotation in the housing about an axis
defining an axial direction of the rotary device. The rotor
assembly includes a rotor and a seal assembly. The rotor includes a
central portion and a plurality of arms extending radially outward
from the central portion. Each arm has a distal end disposed for
sliding engagement with the inner surface of the housing, and at
least one of the arms has a channel defined therein. The seal
assembly is disposed within the channel, and comprises a seal, a
base, and a counterweight mechanism. The seal includes a body and
lip extending outward from the body. The base defines a seal
channel, and includes a fulcrum. The seal is disposed within the
seal channel. The counterweight mechanism is operatively coupled to
the fulcrum, and includes a counterweight and a lever extending
away from the counterweight. Rotation of the rotor causes the
counterweight mechanism to pivot about the fulcrum and causes the
lever to exert a radial inward force on the lip.
[0013] In yet another aspect, a seal assembly for use in a rotary
device including a rotor is provided. The seal assembly includes a
seal, a base, and a counterweight mechanism. The seal includes a
body and a lip extending outward from the body. The base defines a
seal channel, and includes a fulcrum. The seal is disposed within
the seal channel. The counterweight mechanism is operatively
coupled to the fulcrum, and includes a counterweight and a lever
extending away from the counterweight. Rotation of the rotor causes
the counterweight mechanism to pivot about the fulcrum, and causes
the lever to exert a radial inward force on the lip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is perspective view of an exemplary rotary
engine.
[0015] FIG. 2 is an exploded view of the rotary engine shown in
FIG. 1, illustrating a housing and a rotor assembly of the rotary
engine.
[0016] FIG. 3 is an exploded view of the rotary engine's rotor
assembly shown in FIG. 2, illustrating a rotor, a plurality of
rockers, an outer crankshaft, and a main crankshaft of the rotor
assembly.
[0017] FIG. 4 is a cross-sectional view of the rotary engine of
FIG. 1 within a vehicle.
[0018] FIG. 5 is a front view of the rotor shown in FIG. 3.
[0019] FIG. 6 is a partial front view of the rotor shown in FIG. 3,
illustrating one of the rockers in a first position.
[0020] FIG. 7 is a partial front view of the rotor shown in FIG. 3,
illustrating the rocker of FIG. 6 in a second position.
[0021] FIG. 8 is perspective view of an exemplary rocker of the
rotor shown in FIG. 3.
[0022] FIG. 9 is an exploded view of an exemplary outer crankshaft
of the rotor shown in FIG. 3.
[0023] FIG. 10 is a perspective front view of the housing of the
rotary engine shown in FIG. 1.
[0024] FIG. 11 is a perspective rear view of the housing of the
rotary engine shown in FIG. 10 including cooling jackets.
[0025] FIG. 12 is a perspective view of the rotor shown in FIG.
3.
[0026] FIG. 13 is a perspective view of the main crankshaft shown
in FIG. 3.
[0027] FIG. 14 is a front view of an exemplary two-chambered rotor
suitable for use in a rotary engine
[0028] FIG. 15 is a perspective view of an exemplary dual unit
rotary engine including two rotary engines.
[0029] FIG. 16 is a perspective view of an alternative ring plate
suitable for use with the rotary engine shown in FIG. 1.
[0030] FIG. 17 is a perspective view of another alternative ring
plate suitable for use with the rotary engine shown in FIG. 1.
[0031] FIG. 18 is a perspective view of a replacement part suitable
for use with the rotary engine shown in FIG. 1.
[0032] FIG. 19 is a perspective view of an exemplary seal suitable
for use with the rotary engine shown in FIG. 1.
[0033] FIG. 20 is a perspective view of an exemplary housing
suitable for use with rotary-type compressor.
[0034] FIG. 21 is a perspective view of an alternative spur gear
suitable for use with the rotary engine shown in FIG. 1.
[0035] FIG. 22 is a perspective view of an alternative rotor
suitable for use with the rotary engine shown in FIG. 1.
[0036] FIG. 23 is an exploded view of an exemplary housing
including a sleeve suitable for use with the rotary engine shown in
FIG. 1.
[0037] FIG. 24 is a cross-sectional view of an exemplary rotor
suitable for use with the housing and the rotor assembly shown in
FIG. 2, the rotor including a counterbalanced seal assembly.
[0038] FIG. 25 is an enlarged partial view of the rotor shown in
FIG. 24, illustrating details of the counterbalanced seal
assembly.
[0039] FIG. 26 is a side view of an exemplary seal suitable for use
in the counterbalanced seal assembly shown in FIG. 25.
[0040] FIG. 27 is a perspective view of a portion of the seal shown
in FIG. 26
[0041] FIG. 28 is a perspective view of an exemplary counterweight
mechanism suitable for use in the counterbalanced seal assembly
shown in FIG. 25.
[0042] FIG. 29 is a partial cross-sectional view of a rotor arm
including an alternative embodiment of a counterbalanced seal
assembly that includes a control mechanism.
[0043] FIG. 30 is a partial perspective view of a rotor arm
including another alternative embodiment of a counterbalanced seal
assembly.
[0044] FIG. 31 is a partial perspective view of the rotor arm of
FIG. 30 illustrating the counterbalanced seal assembly of FIG. 31
removed from the rotor arm.
[0045] FIG. 32 is a partially exploded view of the counterbalanced
seal assembly of FIG. 31.
[0046] FIG. 33 is a partially exploded view of yet another
alternative embodiment of a counterbalanced seal assembly.
[0047] FIG. 34 is a partial perspective view of a rotor assembly in
which the counterbalanced seal assembly of FIG. 33 is
installed.
[0048] FIG. 35 is an exploded view of yet another alternative
embodiment of a counterbalanced seal assembly.
[0049] FIG. 36 is an end view of the counterbalanced seal assembly
of FIG. 35.
[0050] Although specific features of various embodiments may be
shown in some drawings and not in others, this is for convenience
only. Any feature of any drawing may be referenced and/or claimed
in combination with any feature of any other drawing.
DETAILED DESCRIPTION
[0051] FIG. 1 is a perspective view of an exemplary rotary engine
100, and FIG. 2 is an exploded view of rotary engine 100. Rotary
engine 100 includes a housing 200 for housing other components and
for mounting in a vehicle or other device, a rotor assembly 300
(broadly, a power module), and an output member 600 (broadly, an
output).
[0052] Housing 200 may include a generally cylindrical housing body
202 of 8620, 8514 or other steel or iron alloy. Aluminum or other
suitable materials also could be used. Housing body 202 has a
cylindrical inner wall or surface 204. In some embodiments, inner
wall 204 is defined by a steel insert or sleeve received within an
outer housing body (see, e.g., FIG. 23).
[0053] Housing 200 may be air- or water-cooled. If water-cooled,
housing 200 may have top and bottom water troughs 210 and 220
(FIGS. 10 and 11). A top water jacket 212, which covers top water
trough 210, has an inlet 214 and an outlet 216 (FIG. 10). Likewise,
a bottom water jacket 222, which covers bottom water trough 220,
has an inlet 224 and an outlet 226. The inlets may receive coolant
from a radiator or other heat exchanger, and the outlets return the
coolant to the radiator. Hoses connecting the inlet and outlet to
the radiator are not shown. The troughs may have vanes 218 and 228
of heat conductive material to transfer heat from the housing to
the coolant. The vanes also may direct the coolant to flow from the
inlet to the outlet. In addition, one could change the locations of
the inlet and outlet or the orientation of the vanes 218, 228. In
one embodiment, for example, vanes 218, 228 may extend parallel to
an axial direction of housing 200.
[0054] A front plate 230 and a rear plate 232 enclose housing 200
(FIGS. 1 and 2). Plates 230 and 232 may be 6061 aluminum or other
suitable material. The terms "front" and "rear" are used with
reference to the drawings, not necessarily with reference to a
vehicle or another device in which the rotary engine mounts.
Housing body 202 has circumferentially spaced bores extending into
the front and back of the housing body. Only bores 234 on the front
of housing 200 are visible in FIGS. 2, 4, 10, and 11. Bolts or
other fasteners (not shown) extend through corresponding holes 236
in front plate 230 and lock into the bores. Housing body 202 may
have openings and ports that are discussed in more detail
below.
[0055] Front and rear plates 230 and 232 may include an oil ring
seal groove 238 (only shown on plate 232 in FIG. 2). Corresponding
ring seals (see seal 532 in FIG. 19) seat in the ring seal grooves
to create a seal when the plates attach to housing body 202.
Gaskets (not shown) also may seal the plates to the housing body.
Other devices or systems may be provided to prevent galvanic
corrosion due to the dissimilar metals.
[0056] A rotor assembly 300 (broadly, a power module) is mounted
for rotation within housing body 202. Rotor assembly 300 includes a
rotor 310 that rotates about an axis of rotation within housing
body 202. Rotor 310 may be formed of 8620 or 8514 steel or ductile
iron. Rotor 310 may have four arms 312, 314, 316 and 318 (FIGS. 5,
6, 7, and 12). The distal end of each arm, e.g., end 320 of arm 312
(FIGS. 5 and 7), has two short, spaced-apart extensions 322 and 324
(FIGS. 6 and 7). Outer faces 326 and 328 of extensions 322 and 324
(FIGS. 3, 6, and 7) may have surfaces that conform to inner wall
204 of housing body 202 for sliding engagement with cylindrical
inner wall 204. In the embodiment illustrated in FIG. 3, pressure
plates 330, which may be 9254 steel, seat in the space between
extensions 322 and 324. Spring 332, which may be made of
Incoloy.RTM. alloy, urges pressure plate 330 to push seals 306 and
308 (FIG. 3) to seal against cylindrical inner wall 204. Pressure
plate seals and arm extensions, such as extensions 322 and 324,
seal the distal ends of the arms to the inside cylindrical wall 204
of the housing body 202. Remaining arms 314, 316 and 318 have
similar arrangements.
[0057] Arms 312, 314, 316 and 318 may be formed from two plates 340
and 342 that extend outward from a central portion, i.e., hub 344
(FIG. 12) and form a hollow space 336 between plates 340 and 342.
Only the plates that form arm 312 in FIG. 12 are numbered. The
hollow space is used by outer crankshafts as described below. In
addition, having spaced-apart plates may decrease rotor mass and
increase efficiency.
[0058] Plates for arms 312, 314, 316 and 318 may have aligned
bores. FIG. 12 shows bores 350, 352, 354 and 356 in plate 340. Only
bore 358 in plate 342 is visible. Bores 350, 352, 354 and 356 align
with corresponding bores in plate 342.
[0059] Referring to FIG. 5, a plurality of chambers 360, 362, 364,
and 366 are defined by pairs of adjacent arms 312, 314, 316, and
318, and inner cylindrical wall 204. In the illustrated embodiment,
chamber 360 (FIG. 5) is formed between arms 312 and 318, and the
spaces between arms 312 and 314, 314 and 316 and 316 and 316, form
chambers 362, 364 and 366, respectively.
[0060] A plurality of rockers 370, 372, 374 and 376 are pivotally
connected to rotor 310 for pivoting between a first, inner position
spaced from inner wall 204 (shown in FIG. 6), and a second, outer
position adjacent inner wall 204 (shown in FIG. 7). One of four
rockers 370, 372, 374 and 376 is mounted for pivoting within each
chamber 360, 362, 364 and 366. FIG. 3 shows rocker 376 exploded
from the rotor, FIG. 5 shows each rocker 370, 372, 374 and 376 in
relation to rotor 310, and FIG. 8 shows an enlarged view an
exemplary rocker. Rockers 370, 372, 374 and 376 may be formed from
4032 aluminum or other appropriate material.
[0061] As shown in FIGS. 5 and 8, a pivot pin 380 extends through a
ridge 382 of each rocker 370, 372, 374 and 376 (only one pin
labeled in FIG. 5). Ridge 382 mounts in a rounded portion 384 of
each arm 312, 314, 316 and 318. An outer surface of ridge 382
cooperates with a surface of rounded portion 384 to seal ridge 382
and rounded portion 384 intersection as the rocker pivots. Added
structure may be provided to enhance the seal at ridge 382 such as
a sealing member 428 (FIG. 3) proximate ridge 382 (FIG. 8). Rockers
370, 372, 374 and 376 may have a front groove 404 and side grooves
(e.g., groove 406 shown in FIG. 8). Side compression seals 424 and
426 (FIG. 3) mount in the side grooves and front compression seal
428 seats in front groove 404. Side compression seals 424 and 426
and front compression seal 428 may be 5254 steel. Side compression
seals 424 and 426 contact the inside of front ring plate 396 and
rear ring plate 398 when ring plates 394 and 396 are mounted to the
outside of rotor 310 (FIG. 3). Front compression seal 428 contacts
the rocker face of each rotor arm, e.g., face 368 of arm 312 (FIG.
5). The rocker faces may be arcuate around the axis of each pivot
pin. The rocker faces also close off the space between the two
plates. Seals 306 and 308 (FIG. 3) may seat in circumferential
grooves 334 of ring plates 396 and 398 (only groove 334 in ring
plate 396 is labeled in FIG. 3). Each seal 306 and 308 may have
inward facing portions 504 and 506 (only inward facing portions 504
and 506 on seal 306 are labeled in FIG. 3). Inward facing portions
504 and 506 contact each other to form a seal. Inward facing
portions 504 and 506 may extend from the circumferential grooves
though a notch in the ring plate, e.g., notch 508. When the device
is assembled, seals 306 and 308 seal the outside of chambers 360,
362, 364 and 366.
[0062] One may want to change parts if one of the rocker faces
(e.g., rocker face 368 shown in FIG. 5) becomes damaged or worn.
Therefore, rotor 310 may be designed to accept a replacement part
with an undamaged or unworn face, such as replacement part 378
(shown in FIG. 18).
[0063] Referring again to FIG. 3, front and rear ring plates 396
and 398 cover rotor arms 312, 314, 316 and 318, chambers 360, 362,
364 and 366 and rockers 370, 372, 374 and 376. Ring plates 396 and
398 may be formed of ductile iron. Front ring plate 396 has four
cutouts 484, 486, 488 and 490. Each cutout 484, 486, 488 and 490
aligns with one of bores 350, 352, 354 or 356 in a respective rotor
arm 312, 314, 316 and 318 (shown in FIGS. 6 and 7). Rear ring plate
398 also has four cutouts 496, 498, 500 and 502 (FIG. 3). Each
cutout 496, 498, 500 and 502 aligns with a corresponding cutout on
front ring plate 396.
[0064] Pivot pin 380 may extend into bores, such as bores 394 on
front ring plate 396 (FIG. 3) and to corresponding bores (not
numbered) on rear ring plate 398. Pivot pin 380 may also extend
into recesses, which extend into but not through the ring plates.
Bores 388, 390 and 392 and the other unnumbered bores on the ring
plate can be used for bolting front ring plate 396 to rotor 310.
Corresponding bolts or other fasteners attach rear ring plate 398
to rotor 310. The fasteners (not shown) attach to threaded bores
386 (shown FIGS. 3-7) on rotor arms 312, 314, 316 and 318. The
bores' positions used to attach the ring plates can vary.
[0065] For positioning by hand, dowels may be used to align
appropriate holes, e.g., hole 388 in ring plates 396 or 398, with
the appropriate bore 386. Automated assembly may use different
techniques.
[0066] Referring again to FIG. 8, rocker 376 may include two
spaced-apart pin bosses 410 and 412, which may be integrally formed
as part of rocker 376. Rocker rod pin 414, which may be 4140 steel,
extends through bores 416 in pin boss 410 (only one visible in FIG.
8). Rocker rod pin 414 also extends through the upper bore 420 of
link 418 (shown FIGS. 3 and 8). A lower bore 422 of link 418 is
also shown in FIG. 3. Link 418 also may be 4140 steel. Rockers 370,
372, and 374 may have the same configuration as rocker 376 shown in
FIG. 8.
[0067] Rockers 370, 372, 374 and 376 pivot about their respective
pivot pins, e.g., pin 380 in rocker 376 (FIG. 5). Each rocker 370,
372, 374 and 376 pivots between an outside position, which is close
to inner wall 204 of housing body 202, to an inside position away
from inner wall 204, and back to the outside position. Thus, in
FIG. 5, rockers 370 and 374 are shown in the inside positions, and
rockers 372 and 376 are shown in the outside positions. These
positions are temporary because rockers 370, 372, 374 and 376 pivot
in and out as described below.
[0068] Pivoting of each rocker 370, 372, 374 and 376 rotates a
corresponding outer crankshaft 430, 432, 434 and 436 (FIG. 5).
Likewise, rotating an outer crankshaft pivots its corresponding
rocker. Outer crankshafts 430, 432, 434 and 436 may be made of 4140
steel. In the embodiment illustrated in FIGS. 8 and 9, outer
crankshaft 436 includes an assembly of components, although one or
more of outer crankshafts 430, 432, 434 and 436 may have a unitary
construction. As shown in FIGS. 8 and 9, crankshaft 436 includes
front and rear wheels 440 and 442. Front wheel 440 includes
rearward facing journal 444 that has a tang 446 at its end. Tang
446 seats in tang receiver 448 in rear crank wheel 442 (FIG. 9).
Front first driver or drive member, i.e., front spur gear 450
includes a tang 452 that seats in tang receiving opening 454 in
front wheel 440, and rear first driver or driver member, i.e., rear
spur gear 456 also includes a tang 458 received within its tang
receiving opening (not visible in FIG. 9) in rear crank wheel
442.
[0069] Bolts 460 and 462 (FIG. 5 (only two numbered) and FIGS. 7
and 8) or other fasteners extend through the bolt holes 464 and 466
in front spur gear 450 and through aligned holes 468 and 470 in
front crank wheel 440, through aligned holes 472 and 474 in rear
crank wheel 442 and into hole 476 and 478 in rear spur gear 456.
Threads for engaging the bolts inside the rear spur gear are not
visible. Consequently, the bolts secure the front spur gear, the
front and rear crank assemblies and the rear spur gear
together.
[0070] Front and rear wheels 440 and 442 of each outer crankshaft,
e.g. crankshaft 436, may have an oil groove 480 and 482 (FIGS. 8
and 9) for lubricating the wheels. The oil grooves may receive
lubricant from oil feed 338 (FIG. 12). The oil feed may be angled
for ease of machining. Alternatively, the oil feed could be
straight by drilling it after drilling through arm plates 340 and
344.
[0071] Pressure from gases caused by ignition of fuel in the
combustion chamber associated with rocker 376 causes rocker 376 to
pivot inward (i.e., in FIG. 7, the right side of rocker 376 moves
downward). Accordingly, the rocker drives link 418 against journal
444 of outer crankshaft 436, which rotates the crankshaft. The
parts are dimensioned such that when the rocker reaches its
innermost position, the crankshaft journal is at or near its bottom
position. Continued rotation of the journal drives the rocker
outward. If the rocker is in position other than being pushed by
gas expansion and depending on the position of the rocker in its
cycle, the crankshaft pulls or pushes the rocker.
[0072] A main crankshaft 610 (shown in FIGS. 2, 3, 5 and 13), which
may be 4130 steel, provides power from the engine to power a
vehicle or produce other useful work. The main crankshaft 610 may
be one piece, or an assembly of separately formed pieces that are
connected together. The main crankshaft 610 may include a section
or sleeve 616 (FIG. 3), which has a larger diameter than
intermediate diameter portions 614. Oil grooves 650 and 652 (FIG.
13) at the ends of larger diameter section 616 carries oil for
lubrication. The main crankshaft 610 also includes smaller diameter
flanges 612 and 618 at the crankshaft's ends. In addition, sleeve
616 includes a longitudinal keyway 632 (FIG. 13). Although FIG. 13
shows only one keyway, crankshaft 610 may include more than one
keyway.
[0073] The longitudinal center of main crankshaft 610 may be hollow
to transfer oil to outside the crankshaft and from one oil hole to
another. For example, one or more oil distribution channels 640
(FIG. 13) may extend along the center, larger-diameter section 616
and connect with oil grooves 650 and 652. Likewise, one or more
additional circumferential oil troughs 642 and 644 may extend
around the outside of the main crankshaft's smaller diameter
flanges 612 and 618. Oil feeds 628 and 630 may carry lubricant to
the oil troughs. Flanges 612 and 618 may have keyways 634 and 636.
The ends of the flanges form bolt holes 638, only one of which is
visible in FIG. 13.
[0074] Referring to FIG. 12, a thrust ring 540, which may be
bronze, mounts in thrust ring cavity 542 in rotor 310, and a
corresponding thrust ring (not visible in FIG. 12) mounts on the
other side of rotor 310. Each thrust ring has a bore 544. Main
crankshaft 610 may be mounted to rotor 310 by positioning main
crankshaft 610 inside cavity 542, and sliding thrust rings (e.g.,
thrust ring 542) over main crankshaft 610. A key 546 from each
thrust ring engages keyway 640 of sleeve 616.
[0075] Main crankshaft 610 extends through ring gears 620 and 622
(broady, second drivers or drive members) and ring plates 396 and
398. The ring gears 620 and 622 may be 4140 steel. The main
crankshaft 610 mounts in bores (only bore 510 is visible in FIGS.
6, 7, and 12) in the center of arm plates 340 and 342. The ring
gears may be fixed against the insides of front plate 230 and rear
plate 232 (FIGS. 1 and 2). For example, the ring gears may be fixed
to mounting plate 662, and bolts 660 may secure the ring gears and
mounting plate to the front and rear plates. The ring gears also
may be fixed to other structure.
[0076] The teeth of front spur gear 450 and rear spur gear 456,
which are associated with outer crankshaft 436 and rocker 376,
engage the teeth on ring gears 620 and 622. Likewise, other spur
gears on the other outer crankshafts, e.g., 432, 434, 436,
associated with the other rockers also engage the teeth on the
front or rear ring gear. Because the ring gears are stationary,
spur gear rotation causes the spur gears to revolve around the ring
gears. The connection of the outer crankshafts including their spur
gears to rotor 310 causes the rotor to rotate about the rotor's
axis of rotation. That axis coincides with the main crankshaft's
axis of rotation.
[0077] In the figures, the spur gears travel around the outside of
the ring gear. The ring gear could be a planetary gear with
internal teeth so that the spur gears would travel around the
inside of such a gear. Further, although the drawings show spur
gears engaging a ring gear, the gears could be replaced with other
devices such as belts, chain drives and friction drives capable of
driving or being driven through their interaction.
[0078] The ratio of the number of spur gear teeth to ring gear
teeth can be modified. Doing so changes the angular distance that
rotor 310 travels for each rotation of the spur gears, e.g., gears
450 and 456.
[0079] Flanges 612 and 618 of main crankshaft 610 may extend
through bores 244 and 246 in front and rear plates 230 and 232
(FIG. 2). Having only one flange protrude from housing 200 may be
acceptable, however. The crankshaft flanges may extend through
respective openings 252 and 254 of crankshaft collars 248 and 250.
Fasteners (not shown) extending through openings 256 in front
crankshaft collar 248 engage bores 258 in front plate 230, and
corresponding fasteners secure the rear collar 250 to the rear
plate. Each collar may have seals (not shown) around the inside of
openings 252 and 254. A timing mark mount hole 260 (FIG. 2) also
may be provided.
[0080] Front and rear plates 230 and 232 may include oil ring seal
groove 238 (only shown on plate 232 in FIG. 2). Corresponding ring
seals (e.g., seal 532 shown in FIGS. 2 and 19) seat in the ring
seal grooves to create a seal between the front and rear rotor ring
plates 396 and 398 and the insides of front and rear housing plates
230 and 232 when those plates are attached to housing body 202. The
ring plate seals may include an annular shoulder 530, which faces
and is in contact with the ring plates. The ring plate seals may be
cast iron, silicon graphite, carbon fiber or other appropriate
material. Springs (not shown) may bias the ring plate seals toward
the front and rear ring plates.
[0081] Ring plate seals 532 remain stationary with respect to
housing plates 230 and 232 during rotation of rotor 310. Thus, the
rotor's ring plates 396 and 398 slide on the ring plate seal. The
ring plate seals have a rim shoulder 534 (shown in FIG. 19).
Gaskets (not shown) may also seal plates 230 and 232 to the housing
body 202. Other devices or systems may be provided to prevent
galvanic corrosion due to any dissimilar metals being in contact
with each other.
[0082] FIGS. 16 and 17 show two alternative designs for front and
rear ring plates, designated 492 and 494, respectively. An outer
face 580 of front ring plate 492 includes a boss 582. The boss 582
fits into a corresponding indentation on the housing front or rear
plate that would be modified from end plates 230 or 232 shown in
FIG. 2. Openings such as openings 584, 586 and 588 may serve
several functions. Openings 584 and 586 and corresponding holes in
ring plate 494 are for fasteners (not shown) for attaching the ring
plates to the rotor. Openings 590 and 592 (FIG. 17) are for spur
gear clearance and support. One opening in each quadrant may mount
a pivot pin for the rotor's rockers. Instead of cutouts extending
completely through the ring plates, such as cutouts 484, 486, 488,
and 490 shown in FIG. 3, front and rear ring plates 492 and 494 may
include recesses, such as recess 590 (FIG. 17), defined in an inner
wall of the respective ring plate. Spur gears 594 (FIG. 21), mount
in each recess. Bores 588 and 592 (FIGS. 16 and 17) extend through
respective ring plates 492 and 494 and receive hub 596 of the
corresponding spur gear. A shaft would extend through the bore to
connect a spur gear to the wheel of the outer crankshaft. Openings
(not shown) also could be provided adjacent the spur gears for
spraying lubrication onto the spur gears.
[0083] For the engine to operate, controlled amounts of air and
fuel are injected through intake port 514 (FIGS. 10 and 11) as
rockers, such as rocker 374 (FIG. 5), pivot about their respective
pivot pins (e.g., pivot pin 380) inward. Electronic control may
vary the amount of air and fuel or the air-fuel ratio. A
turbocharger or supercharger could increase the volume of air
(oxygen) through the intake port. As the spur gear on outer
crankshaft 434 revolves about front ring gear 620 (and a
corresponding spur gear revolves about rear ring gear 622), the
outer crankshaft rotates. The outer crankshaft's connection through
a link to rocker 374 pivots the rocker inward. The inward pivoting
causes a pressure decrease in chamber 366 (marked "Intake" chamber
in FIG. 5).
[0084] After chamber 366 receives a predetermined amount of air and
fuel, rotor 310 rotation carries chamber 366 past intake port 514
(FIGS. 10 and 11). Further rotation of the rotor 310 causes outer
crankshaft 434 to begin pivoting rocker 374 outward. Because the
drawings are not animated and the components remain stationary,
consider that chamber 366 has moved to the position where chamber
360 had been in the drawings and that the reference numerals for
the parts that had been there now are used. As rocker (now 376)
pivots outward, the decrease in volume in chamber 360 causes a
corresponding pressure increase (compression) of the air-fuel
mixture in the chamber above the rocker.
[0085] Referring again to FIG. 8, the top surface of the rockers,
e.g., rocker 376, may be coated. In the embodiment illustrated in
FIG. 8, the top surface of rocker 376 has a central combustion
region 402 surrounded by a squish zone 408. In a piston engine, a
squish zone is a narrow section of a combustion chamber in which
the air-fuel mixture is more compressed than in the rest of the
chamber. A squish zone helps direct the flow of a fresh air-fuel
mixture and to improve scavenging (i.e., pushing exhausted gas out
of the cylinder). Here, squish zone 408 is a raised surface
extending outward from surface 402, and conforms to inner wall 204
of housing body 202. This raised surface creates higher pressures
around the extended edges of combustion surface 402.
[0086] Squish zone 408 may create turbulence by compressing the
air-fuel mixture in the zone as the mixture reaches full
compression over central combustion region 402. This may allow more
complete burning of the gaseous mixture to decrease emissions. The
squish zone also may improve exhausting of the remaining burnt
gases. The surface of the squish zone may be 0.010 in. to 0.080 in.
(0.25 mm to 2 mm) (metric equivalents are approximations) above
combustion surface 402 with 0.020 in. to 0.060 in. (0.5 mm to 1.5
mm) possibly preferred.
[0087] Referring to FIGS. 1 and 4, a spark plug 520 extends through
a mount 522 defined in housing body 202, and toward chamber 360
such that a spark from spark plug 520 can ignite the compressed
air-fuel mixture. High-pressure, direct injectors may be installed
into housing 202 in close proximity to the spark plug 520 for
gasoline direct injection. The hot end of the spark plug may
terminate in a recess 524 in inner wall 204 of housing body 202
(shown in FIG. 10). The recess is shown as cylindrical, but could
be sized and shaped to improve combustion. Although the illustrated
embodiment is shown with a single spark plug, rotary engine 100 may
include two or more sparks plugs for each combustion chamber. In
other embodiments, rotary engine may operate based on a diesel
cycle at higher pressures and without a spark plug. Those higher
pressures may require different materials or different dimensions
for the rotary engine's components.
[0088] Spark plug 520 fires at a predetermined time for proper
engine timing. The ignition of the fuel in the presence of air in
chamber 360 causes combustion and creates a substantial increase in
pressure in the chamber. The pressure from the combustion applies a
force on rocker 376, moving rocker 376 to its inward position.
[0089] Through the connection of outer crankshaft tang 436 with
tang receiver 448, the inward movement of rocker 376 rotates outer
crankshaft 442. As a result, spur gears 450 and 456 rotate and
travel along the outside of ring gears 620 and 622 (FIGS. 3 and 5).
This, in turn, causes rotor 310 to rotate.
[0090] Continued rotation of rotor 310 positions the chamber to the
position of chamber 364 in FIG. 5. During this rotor rotation, the
spur gears associated with the rocker (now rocker 372) act on the
link between the outer crankshaft and the rocker to pivot the
rocker outward. The outward pivoting pushes exhaust gases through
exhaust port 516 (FIGS. 2, 10 and 11). This cycle is repeated as
rotor 310 continues to rotate.
[0091] During each revolution of rotor 310, each of the four
chambers sequence through four cycles: intake, compression, power
(i.e., combustion) and exhaust. The timing of the intake,
compression, combustion and exhaust cycles can be modified by
modifying the offset pivot of the rocker link, e.g., link 418
relative to its outer crankshaft 436 and to its rocker 376 (FIG. 8)
and the position of its pivot pin 380. Additionally or
alternatively, the timing of the intake and/or exhaust may be
altered by modifying the configuration (e.g., shape) and/or radial
position of intake port 514 and/or exhaust port 516.
[0092] Because the rocker's pivot is stationary, the pivot also may
create an arc-shaped offset angle. For example, the rockers can
have longer power and intake cycles than their compression and
exhaust cycles. Those cycles may be as follows: intake=100.degree.,
compression=80.degree., combustion=100.degree. and
exhaust=80.degree.. This overlap could allow each combustion cycle
to fire 20.degree. before the previous chamber has finished its
power cycle. This overlap function may allow smoother transitions
between power cycles.
[0093] In addition, the intake and exhaust ports 514 and 516 (FIGS.
10 and 11) may overlap so that new air and fuel enter the
combustion chamber through the intake port as it opens and before
the exhaust port is completely closed-off. This may allow a small
rush of new air-fuel mixture to push out the remaining exhaust
gases drawing in a completely new charge of fuel and air. The
degree of overlap of the intake and exhaust ports 514 and 516 may
be between about 0.degree. to about 24.degree., more suitably
between about 1.degree. and about 20.degree., and even more
suitably, about 8.degree..
[0094] In the illustrated embodiment, only the outer crankshaft
connected to the rocker within the combustion chamber receives
power directly from combustion-caused pressure acting on the
rocker. Through rotation of that outer crankshaft's spur gear
acting on ring gears 620 and 622, rotor 310 rotates. At the same
time, continued rotation of the rotor causes the spur gears of the
other three outer crankshafts to rotate, which, in turn pivots the
rockers associated with those crankshafts inward or outward. As
each rocker and its corresponding spur gear move to the
power/combustion position where the air-fuel mixture ignites,
expanding gases drive the rocker inward. Consequently, that set of
spur gears become the driving gears, and the other spur gears
become driven gears.
[0095] When the rotor assembly 300 is assembled, the rear face of
front ring plate 396 and the front face of rear ring plate 398
engage respective sides of rotor 310. Each side of the rotor 310
may have a sealing groove, such as sealing groove 530 shown in
FIGS. 5-7, that runs along the periphery of the arms. A rotor seal
cord (not shown) may be installed in the sealing grooves on both
sides of rotor 310 to form a seal between the arms 312, 314, 316,
and 318, and ring plates 396 and 398.
[0096] As shown in FIG. 1, when rotary engine 100 is assembled,
main crankshaft 610 extends through collar 248. If the rotary
engine is used on a vehicle, the main crankshaft 610 may be
connected to the rest of the vehicle's drive train, e.g., a
transmission, a clutch or other components. For non-vehicle uses,
such as pumps and compressors, the crankshaft 610 connects to the
driven device. The main crankshaft 610 also could be driven if the
device is used as a compressor or pump, such as compressor 800
described below with reference to FIG. 20. The main crankshaft 610
also may extend out either side or both sides of the housing.
[0097] Various components of the rotary engine may have channels
and openings, such as openings 346 and 348 (FIGS. 6, 7, and 12),
for coolant and lubricant. Such channels and openings may vary with
different engine sizes and designs. The arms also may have oil
jets, e.g., jet 338 (FIG. 12) for providing lubrication in the
chambers. These oil jets may be pressure or movement activated,
allowing oil to pass only when desired. Other physically activated
(pressure or movement) oil jets may be placed on various component
parts, such as the front and rear plates 230 and 232 (FIG. 2) for
controlled oiling of moving parts. Components and parts may have
bushings or bearings (not shown) where needed for reducing
friction, metal to metal contact protection, or holding desired
tolerance specifications. Oil vacuum ports on the front and rear
plates 230 and 232 (FIG. 2) may be placed at the lowest available
gravitational oil collection area, depending on the physical
mounting position of the engine, to extract oil away from moving
parts. Parts also may have cutouts to decrease weight or provide
better heat dissipation.
[0098] Referring to FIG. 4, rotary engine 100 is illustrated in a
vehicle environment. An air intake system 110 may include an air
filter 112 on a throttle body 114, which connects to an intake
manifold 116. Air from the intake system flows into intake chamber
366 (FIG. 5). A fuel injector 126 is positioned near the intake
chamber. The engine may be designed to burn different fuels, e.g.,
gasoline, ethanol, CNG, LNG, propane, or hydrogen. The fuel
injector of such an engine could have separate outlets 128 and 130
for different fuels. Exhaust from chamber 364 (FIG. 5) passes into
an exhaust header 118 and into the remainder of the exhaust system.
A starter motor 120, an alternator 122, and an electronic control
unit (ECU) 124 are also attached to housing 200.
[0099] The size of the engine compartment and the position of the
rotary engine in the engine compartment may affect the various
components' locations insofar as they must fit in the compartment
and may need to be accessible for service.
[0100] Belts or other connectors (not shown) may drive the
alternator and other devices from engine power.
[0101] FIG. 14 is a front view of an exemplary two-chambered rotor
550 suitable for use in a rotary engine. Rotor 550 may rotate one
or more times per each power engine power stroke, depending on the
desired usage of rotor 550. The rotor 550 has two arms 552 and 554
that may be shaped as shown in FIG. 14. The arms form two opposite
chambers 556 and 558. Rockers 560 and 562 mount on respective pins
564 and 566. Outer crankshafts (not shown in FIG. 14) connect to
rockers through linkage similar to that shown in FIG. 8. Each
crankshaft may have spur gears (not shown in FIG. 14) at the outer
crankshaft end that protrudes through bores 568 and 570 from the
rotor. A main crankshaft (not shown in FIG. 14) extends through
center bore 572. Stationary ring gears (not shown in FIG. 14) mount
to stationary housing structure.
[0102] In one position in FIG. 14, the air-fuel mixture is injected
or otherwise enters one of the chambers, e.g., chamber 556. As
rotor 550 rotates, rocker 560 pivots outward to compress the
air-fuel mixture until, at or close to full compression, a spark
ignites the air and fuel. Depending on the desired usage of rotor
550, rotor 550 may rotate with or without exhausting the exhaust
gases until the rotor returns to its initial position, i.e., where
chamber 556 is in FIG. 14. Valves (not shown) may control intake
and exhaust from chambers 556 and 558. One or more valves open to
allow the air-fuel mixture to enter chamber 556, and then one or
more different valves open to allow the exhaust gases to enter the
exhaust system.
[0103] The rotary engine that has been described is a four-stroke
engine, intake, compression, combustion and exhaust. In a
four-stroke piston engine, those strokes occur every two rotations
of the main crankshaft. Two-stroke piston engines complete a cycle
in two movements of the piston, in and out. The rotary engine could
be modified into a two-stroke engine. Two- and four-stroke designs
have advantages and drawbacks relative to each other.
[0104] A typical use of internal combustion engines is in vehicles.
Just as piston engines come in different sizes, compressions, power
rating and other factors for different vehicles, the rotary
engine's specifications can vary. Insofar as the rotary engine
powers generators, pumps, machinery or other devices, the engine
may have different designs. Some might require higher speed but
less low-speed torque. Other application may require high torque at
low speed. Some application may require constant output over long
periods. Adjusting the combustion chamber volume, the size and
pivoting angle of the rockers and other factors of the rotary
engine may be modified to satisfy an engine's requirements.
[0105] At least two ways allow matching output power to power
needs. The first is to have larger combustion chambers with larger
rockers. Increasing the diameter of rotor 310 may allow the rockers
to pivot through a larger angle to increase displacement. Likewise,
increasing the width of the rotor also increases the displacement
of each chamber. Optimizing performance may require balancing the
effect of increasing the rotor's diameter and width. For example,
increasing dimensions weight of all components and may affect other
engine components or engine symmetry.
[0106] Stacking two or more rotor assemblies or power modules along
the main crankshaft also could combine the modules' power output.
In addition, combinations of different sized rotor assemblies or
power modules can be assembled into one unit.
[0107] FIG. 15 shows a duel unit rotary engine 700 comprising a
front unit 702 and rear unit 704. The front unit is bounded by
front plate 706 and center plate 710, and the rear unit is bounded
by rear plate 708 and center plate 710. In FIG. 15, the locations
where combustion occurs are on the same side of the housing, but
they could mount 180.degree. apart. Likewise, with more rotors for
one engine, the location where combustion occurs could be spaced
evenly around each housing, e.g., 120.degree. apart for three
rotors and 90.degree. for four rotors.
[0108] Though the configuration just described are internal
combustion engines, rotary engine 100 may also be utilized in a
compressor. FIG. 20, for example, illustrates a compressor 800
including a housing body 802. Compressors may be free-standing.
Therefore, the compressor may include base 804. The housing body
802 has a cylindrical opening 806 configured to receive a power
module or rotor assembly, such as rotor assembly 300 (shown in FIG.
2). Front and rear housing plates (not shown; similar to plates 230
and 232 in FIG. 2) cover the rotor assembly and cylindrical
opening. Seals 810 and 812 may seal the housing plates to the
housing body, and fasteners (not shown) extending through openings
in the housing plates may attach to bores 808 in the housing body.
A main crankshaft of the rotor assembly (such as main crankshaft
610) extends through the housing plates and connects to a separate
motor or engine. When the device is used as a compressor, the main
crankshaft is driven instead of providing the motive force.
[0109] Housing body 802 includes one or more inlets 820 and 824 and
one or more outlets 826 and 828. These inlets and outlets could be
used for high pressures such as for hydraulic pressurization.
Valves may be provided for any inlets or outlets, and their
construction and operation may depend on the fluid volume and
pressure. Various bores such as bores 830, 832, 836 and 838 may be
provided for fastening related devices, such as inlets and outlets
for lubrication.
[0110] Rotor rotation causes the rockers to pivot in an out. The
inlets are positioned to receive air, other gas or liquid (i.e.,
fluid) either from the atmosphere in the case of air or from a
source of fluid. The fluid flows into one of the rotor chambers as
the rocker pivots inward to lower the pressure. When the rotor
rotates away from the inlet, the rocker pivots outward to compress
the fluid and force it through an outlet. With a four-chambered
rotor, the rotor rotates to another inlet, draws fluid into the
chamber and then compresses the fluid as the rotor moves adjacent
another outlet.
[0111] Four strokes are not necessary. Thus, pressurized fluid can
flow out an outlet at all compression strokes (pivoting outward of
the rocker). Accordingly, the rotor could have two, four, six or
more chambers with a corresponding number of rockers and outer
crankshafts subject to space limitations.
[0112] FIG. 22, for example, illustrates a rotor 910 with eight
chambers. Rotor 910 may be particularly useful as a heavy-duty
diesel unit. Rotor 910 includes eight arms 912, 914, 916, 918, 920,
922, 924 and 926. Pairs of adjacent partially define eight
chambers, such as chamber 930 between arms 914 and 916 and chamber
923 between arms 916 and 918. The inner cylindrical wall (not
shown) of a housing in which rotor 910 is received defines the
outside of each chamber. A rocker, such as rockers 934 and 936, is
pivotally mounted near the distal end of each arm 912, 914, 916,
918, 920, 922, 924 and 926. Rockers are configured to pivot inward
and outward of their respective chambers, such as chamber 930.
Rocker 934 is illustrated in an inward position in FIG. 22, and
rocker 936 is illustrated in an outer position in FIG. 22.
[0113] Rotor 910 is formed of front plate 940 and a corresponding
rear plate, which is not visible in FIG. 22. Bores, such as bores
942 and 944, extend through the rotor's front plate, and
corresponding and aligned bores (not shown) extend through the rear
plate. Properly sized wheels (not shown in FIG. 22) mount in the
bores, and spur gears (not shown in FIG. 22) mount to the wheels
and extend out of the bores. The spur gears engage a ring gear
mounted on a main crankshaft extending through central bore 946,
and rotate as the rotor 910 rotates about its axis. Linkages
between the wheels and the rockers cause the rockers to pivot in
and out of their respective chambers as the rotor rotates. When
fuel ignites in the chamber that is then the power chamber, force
from the expanding gas on the rocker rotates the wheels and spur
gear. That rotation acts on the ring gear to rotate the rotor.
[0114] The rotor may have additional bores such as bores 950 and
952 to decrease weight. The bores also may carry lubricant.
[0115] The outside of each arm that contacts or is close to contact
with the cylindrical wall of the housing may have two grooves,
e.g., grooves 958 and 960, which receive seals (not shown). Other
seals for sealing the chambers and the rotor itself are not
shown.
[0116] In the eight-chamber version, the air-fuel mixture ignites
simultaneously in two chambers on opposite sides of the housing.
Thus, during each rotor rotation, each chamber completes eight
cycles (intake, compression, power, exhaust, intake, compression,
power, and exhaust). Engines with 12, 16 or more chambers per rotor
are contemplated. They may be particularly useful for large and
heavy equipment such as earth movers, mining dump trucks, and
cranes.
[0117] FIG. 23 is an exploded view of an exemplary housing 2300
suitable for use in rotary engine 100. Housing 2300 is
substantially similar to housing 200 described above with reference
to FIGS. 1-2, except housing 2300 includes a housing body 2302 and
a sleeve 2304 received within housing body 2302. Sleeve 2304 is
sized and shaped to interface statically, via a tight tolerance
press or clamp, with housing body 2302. Sleeve 2304 is configured
to receive a rotor assembly, such as rotor assembly 300, and act as
an intermediary part between housing body 2302 and rotor assembly
300.
[0118] Housing body 2302 and sleeve 2304 each include respective
inlets or intake ports 2306, 2308, outlets or exhaust ports 2310,
2312, and spark plug mounts 2314, 2316. When sleeve 2304 is coupled
to housing body 2302, inlet 2308, outlet 2312, and spark plug mount
2316 of sleeve 2304 align with inlet 2306, outlet 2310, and spark
plug mount 2314 of housing body 2302, respectively.
[0119] FIG. 24 is a cross-sectional view of an exemplary rotor 2400
suitable for use with housing 200 and rotor assembly 300 (both
shown in FIG. 2). Although rotor 2400 is described with reference
to housing 200 shown in FIG. 2, it is understood that rotor 2400
may be utilized in other rotary engine housings, such as housing
2300 shown in FIG. 23. Rotor 2400 is substantially similar to rotor
310 described above with reference to FIGS. 3-7 and 12, except
rotor 2400 includes a counterbalanced seal assembly 2402 configured
to improve performance of rotary engine 100 and increase the
service life of a corresponding crossover seal within rotary engine
100.
[0120] As shown in FIG. 24, rotor 2400 includes a plurality of arms
2404 extending radially outward from a central portion or hub 2406.
Each arm 2404 extends arcuately from hub 2406 to a respective
distal end 2408 disposed for sliding engagement with inner wall or
surface 204 of housing 200 (FIGS. 1-2). Rotor 2400 may be formed of
the same materials as rotor 310 described above with reference to
FIGS. 3-7 and 12. Further, rotor 2400 may be formed of two plates
similar to rotor 310.
[0121] Each arm 2404 has a bore 2410 defined therein that extends
axially through rotor 2400. Each bore 2410 is sized and shaped to
receive an outer crankshaft, such as crankshaft 436 (shown in FIGS.
5-9), therein. Each arm 2404 also defines a rounded portion 2412
configured to receive a portion of a rocker, such as rocker 376
(shown in FIG. 8).
[0122] Distal end 2408 of each arm 2404 includes an outer surface
2414 shaped complementary to inner wall 204 of housing 200. Distal
end 2408, specifically, outer surface 2414, of each arm 2404 is
disposed for sliding engagement with inner wall 204 of housing body
202. A seal channel 2416 is defined in each arm 2404, and extends
radially inward from outer surface 2414. In the embodiment shown in
FIGS. 24 and 25, a pair of cavities 2418 is also defined within
each arm 2404. Each cavity 2418 extends circumferentially from
opposite sides of seal channel 2416. Seal channel 2416 and cavities
2418 are configured to receive a counterbalanced seal assembly
2402, as described in more detail below. Only one counterbalanced
seal assembly 2402 is shown in FIG. 24, although it is understood
that each arm 2404 may include a counterbalanced seal assembly
2402. In other embodiments, cavities 2418 may be omitted from arms
2404 (see, e.g., FIGS. 30 and 31).
[0123] Rotor 2400 is configured to be assembled as part of a rotor
assembly, such as rotor assembly 300, and mounted for rotation
within an engine housing, such as housing 200 (FIGS. 1-2). When
rotor 2400 is assembled within rotor assembly 300 and mounted
within housing 200, rotor 2400 is configured to operate in
substantially the same manner as rotor 310 described above with
reference to FIGS. 3-7 and 12. Specifically, each arm 2404 is
configured to be pivotally coupled to a rocker, such as rocker 376
(shown in FIG. 8), which is operably coupled to an outer
crankshaft, such as crankshaft 436 (shown in FIGS. 5-9), received
within bores 2410. The outer crankshafts are configured to engage
second drivers or drive members (e.g., ring gears 620 and 622)
mounted to housing 200. The inward and outward pivoting of rockers
causes the outer crankshafts to rotate, and the outer crankshafts
engage the second drive members to rotate rotor 2400. An output
member, such as main crankshaft 610, is operably coupled to rotor
2400, and rotates upon rotation of rotor 2400.
[0124] FIG. 25 is an enlarged view of distal end 2408 of arm 2404,
illustrating details of seal channel 2416, cavities 2418, and
counterbalanced seal assembly 2402. As shown in FIG. 25,
counterbalanced seal assembly 2402 includes a crossover or apex
seal 2420 and a counterweight mechanism 2422.
[0125] FIG. 26 is a side view of seal 2420, and FIG. 27 is a
perspective view of a portion of seal 2420. In the illustrated
embodiment, seal 2420 has a generally T-shaped cross-section, and
includes a head 2424 and a stem 2426 extending generally
perpendicular from head 2424. Head 2424 defines an outer surface
2428 configured to sealingly engage inner wall 204 of housing body
202. Stem 2426 defines a pair of grooves 2430 extending inward from
laterally opposite sides of stem 2426.
[0126] In the illustrated embodiment, head 2424 extends a width or
arc length 2432 in a lateral direction (i.e., a circumferential
direction of rotor 2400) that is greater than the circumferential
width of intake port 514 and the circumferential width of exhaust
port 516 (both shown in FIG. 11). As used with reference to intake
and exhaust ports 514, 516, the term circumferential width refers
to the width of the respective port as measured in the
circumferential direction of housing body 202. Seal 2420 thereby
maintains a constant seal with inner wall 204, and inhibits fluid
flow around seal 2420 that might otherwise occur via intake and
exhaust ports 514, 516.
[0127] In the illustrated embodiment, seal 2420 includes two
separate pieces capable of moving or sliding in a radial direction
independently of one another. Specifically, seal 2420 includes a
first sealing member 2434 and a second sealing member 2436. First
sealing member 2434 and second sealing member 2436 are positioned
adjacent one another in seal channel 2416, and abut one another
along respective engaging surfaces 2438, 2440. In the illustrated
embodiment, first sealing member 2434 and second sealing member
2436 are not physically linked, adhered, or otherwise connected to
one another, and are free to move or slide past one another in a
radial direction. In other embodiments, seal 2420 may have a
unitary construction--i.e., seal 2420 may be formed from a single
piece of material. Seal 2420 may be constructed from a variety of
suitable materials, such as ductile iron.
[0128] FIG. 28 is a perspective view of counterweight mechanism
2422. In the illustrated embodiment, counterweight mechanism 2422
includes a counterweight 2442 and a lever 2444 extending away from
counterweight 2442. Counterweight 2442 has a generally cylindrical
shape, and is sized to be received within one of cavities 2418. In
other embodiments, counterweight 2442 may be shaped other than
generally cylindrical. Lever 2444 extends outward from
counterweight 2442, and is sized and shaped to be received within
one of grooves 2430 defined by stem 2426. Together, counterweight
2442 and lever 2444 define a pair of longitudinally or axially
extending grooves 2446. As described in more detail herein, grooves
2446 are configured to cooperate with a portion of the arms of
rotor 2400, such as arm 2404, to cause counterweight mechanism 2422
to pivot in response to rotation of rotor 2400. Counterweight
mechanism 2422 is suitably constructed from a relatively high
density material, including, but not limited to, steel, iron, lead,
and combinations thereof.
[0129] Referring again to FIG. 25, arm 2404 includes a fulcrum 2448
configured to pivotally engage counterweight mechanism 2422 at a
pivot point. In the illustrated embodiment, fulcrum 2448 includes a
support 2450 extending radially inward from distal end 2408 of arm
2404. Support 2450 is disposed between one of cavities 2418 and
seal channel 2416, and partially defines seal channel 2416 and one
of cavities 2418.
[0130] Seal channel 2416 extends radially inward from outer surface
2414, and is sized and shaped to receive seal 2420. In the
illustrated embodiment, seal channel 2416 extends from outer
surface 2414 to a radial depth that is greater than a radial length
of seal 2420. Seal channel 2416 allows radial displacement of seal
2420, for example, as a result of centrifugal forces imparted on
seal 2420 from rotation of rotor 2400. In the illustrated
embodiment, seal channel 2416 has a T-shaped cross-section
corresponding to the T-shaped cross-section of seal 2420, although
seal channel 2416 may have any suitable configuration that enables
counterbalanced seal assembly 2402 to function as described herein.
Each cavity 2418 is defined within arm 2404, and extends axially
through arm 2404. Cavities 2418 extend circumferentially into arm
2404 from opposite sides of seal channel 2416. Each cavity 2418 is
sized and shaped to receive counterweight 2442.
[0131] In operation, seal 2420 is configured to sealingly engage
inner wall 204 of housing body 202, and thereby inhibit fluid flow
between adjacent chambers defined by arm 2404. Seal 2420 is
configured to slidingly engage inner wall 204 of housing body 202
as rotor 2400 rotates, and maintain a constant seal with inner wall
204. Seal 2420 exerts a contact pressure on inner wall 204 to
maintain the seal between adjacent chambers. As the rotational
speed of rotor 2400 increases, centrifugal forces acting on seal
2420 increase, and cause the contact pressure between seal 2420 and
inner wall 204 to increase. Such contact pressure, if not
controlled, can cause seal 2420 to wear quickly, and reduce the
service lifetime of seal 2420.
[0132] Counterweight mechanism 2422 is configured to control the
radial displacement of seal 2420 resulting from rotation of rotor
2400, and control the contact pressure exerted by seal 2420 on
inner wall 204 resulting from rotation of rotor 2400. Specifically,
the center of gravity of counterweight mechanism 2422 is offset
towards counterweight 2442. As a result, centrifugal forces acting
on counterweight mechanism 2422 cause counterweight mechanism 2422
to pivot about a pivot point defined by fulcrum 2448. The
engagement between lever 2444 and seal 2420 along groove 2430
limits the radial outward displacement of seal 2420 resulting from
rotation of rotor 2400, thereby limiting the contact pressure
between seal 2420 and inner wall 204.
[0133] In the illustrated embodiment, counterbalanced seal assembly
2402 includes two counterweight mechanisms 2422 disposed on
laterally opposite sides of seal 2420. Each counterweight mechanism
2422 engages one of forward and rear sealing members 2434, 2436
(FIG. 26) within groove 2430. The two counterweight mechanisms 2422
enable independent radial movement of first sealing member 2434 and
second sealing member 2436, thereby enabling a contact-pressure
differential between first sealing member 2434 and second sealing
member 2436. In other embodiments, counterbalanced seal assembly
2402 may include only a single counterweight mechanism.
[0134] As noted above, lever 2444 is operatively coupled to seal
2420 via an engagement between lever 2444 and groove 2430 defined
in seal 2420. In other embodiments, lever 2444 may be operatively
coupled to seal 2420 by any suitable means that enables
counterbalanced seal assembly 2402 to function as described herein.
In one embodiment, for example, counterweight mechanism 2422 is
hingedly coupled to seal 2420 by one or more pins (see, e.g., FIGS.
35 and 36).
[0135] FIG. 29 is a partial cross-sectional view of a rotor arm
2900 illustrating another embodiment of a counterbalanced seal
assembly 2902 suitable for use with rotor 2400 (FIGS. 24 and 25).
Rotor arm 2900 and counterbalanced seal assembly 2902 are
substantially identical to rotor arm 2404 and counterbalanced seal
assembly 2402 described with reference to FIGS. 24-28, except
counterbalanced seal assembly 2902 includes a control mechanism
2904. As such, components illustrated in FIG. 29 identical to
components shown in FIGS. 24-28 are identified with the same
reference numbers.
[0136] Control mechanism 2904 is configured to selectively control
the contact pressure between seal 2420 and inner wall 204 of
housing body 202 by exerting a variable radial force on seal 2420.
In the illustrated embodiment, control mechanism 2904 is operably
coupled to seal 2420 via counterweight mechanism 2422, and controls
the contact pressure between seal 2420 and inner wall 204 by
exerting a variable radial force on counterweight 2442. By exerting
a variable radial force on counterweight 2442, control mechanism
2904 facilitates controlling the radial displacement of
counterweight 2442 within cavity 2418, and thereby enables control
of the radial displacement of seal 2420. In other embodiments,
control mechanism 2904 may be operably coupled to seal 2420 by an
intermediate linking member other than counterweight mechanism
2422. In some embodiments, for example, control mechanism 2904 is
coupled to seal 2420 by a linking arm, such as lever 2444. In other
words, counterweight 2442 may be omitted from counterbalanced seal
assembly 2902, and control mechanism may be coupled to seal 2420
via lever 2444.
[0137] Control mechanism 2904 may include any suitable mechanism
configured to exert a variable radial force on seal 2420. In some
embodiments, control mechanism 2904 includes an actuator 2906
operably coupled to seal 2420 either directly or indirectly by one
or more intermediate linking members, such as counterweight
mechanism 2422. Although actuator 2906 is illustrated within cavity
2418 proximate counterweight 2442, actuator 2906 may be disposed
remote from counterweight 2442, such as within hub 2406 of rotor
2400 (FIG. 25) or within housing body 202 (FIG. 2).
[0138] Actuator 2906 may be actuable by a variety of suitable
means, including, for example, mechanical, hydraulic, pneumatic,
magnetic, and combinations thereof. In some embodiments, for
example, actuator 2906 may include a pneumatic actuator operably
coupled to seal 2420 via counterweight mechanism 2422. In another
embodiment, actuator 2906 may include a magnet or electromagnet
configured to magnetically interact with counterweight 2442 to
control the radial displacement of counterweight 2442 within cavity
2418.
[0139] In other embodiments, actuator 2906 may be actuable in
response to one or more environmental conditions within rotary
engine 100. In the illustrated embodiment, for example, actuator
2906 includes a bimetallic strip (broadly, a multi-layer metallic
strip) operably coupled to counterweight 2442, and configured to
bend outward and inward in a radial direction in response to
temperature changes within the rotary engine. The actuator 2906 is
thereby configured to exert a variable radial force on
counterweight 2442 based on a temperature within rotary engine 100.
The layers of the bimetallic strip may be constructed from any
suitable material that enables the bimetallic strip to exert a
variable radial force on counterweight 2442 in response to
temperature changes within rotary engine 100. In one embodiment,
for example, one layer is constructed from steel and the other
layer is constructed from copper or a copper alloy, such as brass.
In the illustrated embodiment, control mechanism 2904 includes two
bimetallic strips, although control mechanism 2904 may include any
suitable number of bimetallic strips that enables control mechanism
2904 to function as described herein, such as a single bimetallic
strip.
[0140] In some embodiments, actuator 2906 may be operably coupled
to and controlled by a computing device, such as ECU 124 (shown in
FIG. 4), to selectively control the contact pressure between seal
2420 and inner wall 204 of housing body 202. For example, ECU 124
may be programmed to vary the radial force applied by actuator 2906
to seal 2420 at specified times and/or rotational positions during
a single stroke or revolution of rotor 2400. The ECU 124 may be
programmed to vary the radial force applied by actuator 2906 to
seal 2420 based upon at least one of a rotational position of seal
2420, a rotational position of rotor 2400, a rotational position of
main crankshaft 610 (shown in FIGS. 1-3), and combinations thereof.
Control mechanism 2904 can thereby provide precise control of the
contact pressure between seal 2420 and inner wall 204 at various
times during a single revolution of rotor 2400.
[0141] FIG. 30 is partial perspective view of a rotor arm 3000
illustrating another embodiment of a counterbalanced seal assembly
3002 suitable for use in a rotary device, such as rotary engine 100
(FIGS. 1 and 2) and compressor 800 (FIG. 20). FIG. 31 is a partial
perspective view of rotor arm 3000 illustrating counterbalanced
seal assembly 3002 removed from rotor arm 3000. As described in
more detail herein, the configuration of counterbalanced seal
assembly 3002 facilitates installation, removal, and replacement of
counterbalanced seal assembly 3002 and the components thereof.
[0142] Rotor arm 3000 extends radially outward from the central
portion or hub of a rotor, such as rotor 2400 (FIGS. 24 and 25), to
a distal end 3004 of rotor arm 3000. Rotor arm 3000 may include a
bore (not shown) similar to bore 2410 (FIG. 24) for receiving an
outer crankshaft, such as crankshaft 436 (FIGS. 5-9). Rotor arm
3000 defines a rounded portion 3006 configured to receive a portion
of a rocker, such as rocker 376 (shown in FIG. 8).
[0143] Distal end 3004 of rotor arm 3000 includes an outer surface
3008 shaped complementary to the inner wall or surface of a rotary
device housing, such as housing 200 (FIGS. 1 and 2) or housing 2300
(FIG. 23). Distal end 3004 is configured for sliding engagement
with the inner wall or surface of a rotary device housing, such as
housing 200 (FIGS. 1 and 2) or housing 2300 (FIG. 23).
[0144] As shown in FIG. 31, rotor arm 3000 includes a pair of
opposing interior side surfaces 3010, 3012, a radial inner surface
3014 extending between interior side surfaces 3010, 3012, and a
pair of ledges 3016 each extending outward from a respective side
surface 3010, 3012. Side surfaces 3010, 3012, radial inner surface
3014, and ledges 3016 define a seal assembly channel 3018 in rotor
arm 3000. Seal assembly channel 3018 extends radially inward from
outer surface 3008, and extends axially through rotor arm 3000 such
that counterbalanced seal assembly 3002 can be inserted or removed
from either side of rotor arm 3000. Seal assembly channel 3018 is
configured to receive counterbalanced seal assembly 3002. In
particular, counterbalanced seal assembly 3002 is configured to
slide in and out of the seal assembly channel 3018 in an axial or
longitudinal direction, indicated by arrow 3020 in FIG. 31, to
facilitate installation, removal, and replacement of the entire
assembly. Axial direction 3020 is parallel to the axis about which
rotor arm 3000 rotates during operation. As shown in FIGS. 30 and
31, rotor arm does not include cavities 2418 (FIG. 25) because all
components of counterbalanced seal assembly 3002 are received
within seal assembly channel 3018. That is, seal assembly channel
3018 is sized and shaped to receive each element of counterbalanced
seal assembly 3002.
[0145] FIG. 32 is a partially exploded view of counterbalanced seal
assembly 3002. As shown in FIG. 32, counterbalanced seal assembly
3002 includes a crossover or apex seal 3022, a base 3024, and a
plurality of counterweight mechanisms 3026.
[0146] In the illustrated embodiment, seal 3022 has a generally
rectangular cross-section, and includes a body 3028 and a pair of
lips 3030 extending transversely outward from opposite sides of
body 3028. Only one of lips 3030 is visible in FIG. 32. Body 3028
extends in axial direction 3020 from a first end 3032 of seal 3022
to a second end 3034 of seal 3022. Body 3028 defines a radial inner
surface 3036 and a radial outer surface 3038. In operation, radial
outer surface 3038 sealingly engages the inner wall of a rotary
device housing, such as housing 200 (FIGS. 1 and 2) or housing 2300
(FIG. 23), to inhibit fluid flow between adjacent chambers of a
rotary device, such as chambers 360, 362, 364, and 366 (FIG.
5).
[0147] Additionally, body 3028 extends beyond rotor arm 3000 in
axial direction 3020. More specifically, body 3028 has a length in
axial direction 3020 that is greater than a length of seal assembly
channel 3018 in axial direction 3020. First end 3032 and second end
3034 of seal 3022 are thereby configured to sealingly engage a face
plate of a rotary device, such as front and rear plates 230, 232 of
housing 200 or ring plates 396, 398 (all shown in FIG. 2), to
inhibit fluid flow around first end 3032 and second end 3034 of
seal 3022.
[0148] A groove 3040 is defined along radial inner surface 3036 of
body 3028. Groove 3040 extends axially from first end 3032 of seal
3022 to second end 3034 of seal 3022. Groove 3040 is configured to
cooperate with base 3024 to maintain alignment of seal 3022 within
counterbalanced seal assembly 3002, as described in more detail
herein.
[0149] Each lip 3030 extends transversely outward from a respective
side of seal 3022. Each lip 3030 is configured to be slidably
received between at least one counterweight mechanism 3026 and base
3024. As shown in FIG. 32, each lip 3030 has a length in axial
direction 3020 less than the length of body 3028 in axial direction
3020. In particular, each lip 3030 has substantially the same
length in axial direction 3020 as seal assembly channel 3018 and
base 3024. In operation, centrifugal forces imparted on seal 3022
from rotation of the rotor in which counterbalanced seal assembly
3002 is installed urge seal 3022 in a radially outward direction.
The engagement between lips 3030 and counterweight mechanism 3026
retains seal 3022 within rotor arm 3000, and further controls the
radial displacement of seal 3022, as described in more detail
below.
[0150] In the illustrated embodiment, seal 3022 has a unitary
construction. That is, seal 3022 is formed from a single piece of
material, such as ductile iron. In other embodiments, seal 3022 may
have a modular construction. That is, seal 3022 may include
multiple sealing members similar to seal 2420 (FIGS. 25-27).
[0151] Base 3024 includes a pair of opposing sidewalls 3042, 3044
and a radial inner wall 3046 extending between and interconnecting
sidewalls 3042, 3044. When counterbalanced seal assembly 3002 is
disposed within seal assembly channel 3018, each sidewall 3042,
3044 is positioned adjacent to an interior side surface 3010, 3012
of rotor arm 3000, and extends from radial inner surface 3014 of
rotor arm 3000 to a respective ledge 3016. Radial inner wall 3046
is positioned adjacent radial inner surface 3014 of rotor arm 3000.
Base 3024 is sized and shaped complementary to seal assembly
channel 3018 such that sidewalls 3042, 3044 and radial inner wall
3046 are flush with interior side surfaces 3010, 3012 and radial
inner surface 3014, respectively. The configuration of base 3024
thereby facilitates sliding counterbalanced seal assembly 3002 in
axial direction 3020 to install, remove, and replace
counterbalanced seal assembly 3002.
[0152] Sidewalls 3042, 3044 and radial inner wall 3046 define a
seal channel 3048 configured to receive seal 3022. Seal channel
3048 has a generally rectangular cross-sectional shape
corresponding to the cross-sectional shape of seal 3022, although
seal channel 3048 and seal 3022 may have any suitable configuration
that enables counterbalanced seal assembly 3002 to function as
described herein.
[0153] As shown in FIG. 32, base 3024 also includes a plurality of
fulcrums 3050. Each fulcrum 3050 is configured to pivotally engage
a counterweight mechanism 3026 along a radially inward surface of
fulcrum 3050. Each fulcrum 3050 is coupled to one of sidewalls
3042, 3044. The illustrated embodiment includes four fulcrums 3050,
each fulcrum 3050 corresponding to one counterweight mechanism
3026. Two fulcrums 3050 are coupled to each sidewall 3042, 3044 of
base 3024 in the illustrated embodiment. Fulcrums 3050 coupled to a
common sidewall are spaced from one another in axial direction
3020, and are also aligned with one another in axial direction
3020. In the illustrated embodiment, base 3024 is constructed from
aluminum, and each fulcrum 3050 is constructed from a hardened
steel pin that is pressed into one of sidewalls 3042, 3044. In
other embodiments, base 3024 and fulcrum 3050 may be constructed
from any suitable materials that enable counterbalanced seal
assembly 3002 to function as described herein.
[0154] Base 3024 also includes a ridge 3052 protruding radially
outward from radial inner wall 3046. Ridge 3052 extends axially
along the entire length of base 3024, and is sized and shaped to be
received in groove 3040. Seal 3022 is configured to slide in axial
direction 3020 along ridge 3052. Ridge 3052 facilitates maintaining
alignment of seal during installation and removal of seal 3022, and
also during operation of a rotary device in which counterbalanced
seal assembly 3002 is installed.
[0155] As shown in FIGS. 30 and 31, base 3024 has substantially the
same axial length as seal assembly channel 3018, and is coterminous
with the sides of rotor arm 3000. Base 3024 also has the same axial
length as lips 3030 of seal 3022.
[0156] Each counterweight mechanism 3026 includes a counterweight
3054 and a lever 3056 extending away from counterweight 3054. A
notch 3058 is defined in counterweight mechanism 3026 between
counterweight 3054 and lever 3056. Notch 3058 is sized and shaped
to receive one of fulcrums 3050 therein to provide a pivot point
about which counterweight mechanism 3026 pivots.
[0157] As shown in FIG. 32, each counterweight mechanism 3026 is
disposed between a corresponding fulcrum 3050 and base 3024
(specifically, radial inner wall 3046 of base 3024). Each
counterweight mechanism 3026 is pivotally coupled to one of
fulcrums 3050, and is configured to pivot about a pivot axis 3060
that is substantially perpendicular to axial direction 3020.
Counterweight mechanism 3026 is suitably constructed from a
relatively high density material, including, but not limited to,
steel, iron, lead, and combinations thereof.
[0158] Counterweight mechanisms 3026 are configured to control the
radial displacement of seal 3022 resulting from rotation of rotor
arm 3000, and control the contact pressure exerted by seal 3022 on
the inner wall of a rotary device housing resulting from rotation
of rotor arm 3000. Specifically, the center of gravity of each
counterweight mechanism 3026 is offset towards counterweight 3054.
As a result, centrifugal forces acting on counterweight mechanisms
3026 cause counterweight mechanisms 3026 to pivot about pivot axis
3060 defined by a corresponding fulcrum 3050. As rotor arm 3000
rotates, centrifugal forces acting on counterweight mechanisms 3026
cause counterweights 3054 to rotate in a radially outward
direction, and cause levers 3056 to rotate in a radially inward
direction. Levers 3056 engage lips 3030 of seal 3022, and exert a
radially inward force on lips 3030, limiting the radial outward
displacement of seal 3022. Counterweight mechanisms 3026 thereby
limit the contact pressure between seal 3022 and the inner wall of
a rotary device housing.
[0159] In the illustrated embodiment, counterbalanced seal assembly
3002 includes four counterweight mechanisms 3026. Two counterweight
mechanisms 3026 are operatively coupled to each sidewall 3042, 3044
of base 3024 via fulcrums 3050. Counterweight mechanisms 3026
coupled to a common sidewall are oriented such that counterweights
3054 of counterweight mechanisms 3026 face each other. That is,
each counterweight 3054 extends from notch 3058 towards the other
counterweight mechanism 3026 coupled to the common sidewall.
[0160] As noted above, counterbalanced seal assembly 3002 is
configured to slide in and out of seal assembly channel 3018 in
axial direction 3020. The configuration of counterbalanced seal
assembly 3002 facilitates installation, removal, and replacement of
counterbalanced seal assembly 3002 and the components thereof. In
particular, seal 3022 and counterweight mechanisms 3026 are coupled
to a common structure (i.e., base 3024). More specifically, seal
3022 is retained within seal channel 3048 by an engagement between
counterweight mechanism 3026 and lips 3030, and counterweight
mechanisms 3026 are operatively coupled to base 3024 by fulcrums
3050. As a result, all components of counterbalanced seal assembly
3002 (i.e., base 3024, seal 3022, and counterweight mechanisms
3026) can be moved together as a single unit or module (e.g., by
moving base 3024), for example, during installation or removal of
counterbalanced seal assembly 3002.
[0161] Additionally, because counterweight mechanisms 3026 are
supported within base 3024, counterweight mechanisms 3026 do not
need to be aligned with separate cavities, holes, or slots in rotor
arm 3000 during installation of counterbalanced seal assembly 3002.
Further, because lips 3030 of seal 3022 are configured to slide
between counterweight mechanisms 3026 and base 3024, counterweight
mechanisms 3026 do not need to be aligned with grooves or channels
in seal 3022 during installation or replacement of seal 3022. As a
result, seal 3022 can be easily installed or replaced without
removing the other components of counterbalanced seal assembly 3002
from rotor arm 3000. In other words, seal 3022 is configured to
slide in axial direction 3020 independently of base 3024 and
counterweight mechanisms 3026.
[0162] FIG. 33 is a partially exploded view of another embodiment
of a counterbalanced seal assembly 3300 suitable for use in a
rotary device, such as rotary engine 100 (FIGS. 1 and 2) and
compressor 800 (FIG. 20).
[0163] As shown in FIG. 33, counterbalanced seal assembly 3300
includes a crossover or apex seal 3302, a base 3304, a plurality of
counterweight mechanisms 3306, and a pair of end seals 3308.
[0164] Seal 3302 is substantially identical to seal 3022 described
above with reference to FIGS. 30-32, except seal 3302 has end
grooves 3310 defined therein. As such, components of seal 3302
illustrated in FIG. 33 identical to components shown in FIGS. 30-32
are identified with the same reference numbers.
[0165] Each end groove 3310 extends axially inward into body 3028
of seal 3302 from one of first end 3032 and second end 3034, and
extends radially through body 3028 from radial outer surface 3038
to radial inner surface 3036. Each end groove 3310 adjoins groove
3040 defined along radial inner surface 3036 of body 3028, forming
a single, continuous groove. Each end groove 3310 is sized and
shaped to receive a portion of one of end seals 3308.
[0166] Base 3304 is substantially identical to base 3024 described
above with reference to FIGS. 30-32, except base 3304 does not
include ridge 3052 (FIG. 32), and base 3304 has an end seal channel
3312 defined therein. As such, components of base 3304 illustrated
in FIG. 33 identical to components shown in FIGS. 30-32 are
identified with the same reference numbers. End seal channel 3312
extends radially inward into radial inner wall 3046 of base 3304,
and extends axially for the entire axial length of base 3304. End
seal channel 3312 is sized and shaped to receive a portion of each
end seal 3308 therein.
[0167] Counterweight mechanisms 3306 are identical to counterweight
mechanisms 3026 described with reference to FIGS. 30-32.
[0168] Each end seal 3308 is positioned between seal 3302 and base
3304, and is disposed within groove 3040, one of end grooves 3310,
and end seal channel 3312. In the illustrated embodiment, each end
seal 3308 has an "L"-shaped cross-section corresponding to the
shape of the continuous groove defined by groove 3040 and end
grooves 3310. As described in more detail herein, end seals 3308
are configured to form a seal around ends 3032, 3034 of seal 3302,
and facilitate maintaining the seal at relatively low
temperatures.
[0169] Each end seal 3308 includes a first, sealing end 3314 and a
second, non-sealing end 3316 distal from sealing end 3314. Sealing
end 3314 of each end seal 3308 is configured to sealingly engage a
face plate, such as front plate 230 or rear plate 232 (FIG. 2), of
a rotary device in which counterbalanced seal assembly 3300 is
installed. End seals 3308 are oriented with non-sealing ends 3316
positioned proximate one another.
[0170] A biasing member, such as a spring (not shown), is disposed
between end seals 3308. More specifically, a biasing member is
disposed between non-sealing ends 3316 of end seals 3308, and
biases end seals 3308 towards a respective face plate, such as
front plate 230 or rear plate 232 (FIG. 2), of the rotary device in
which counterbalanced seal assembly 3300 is installed.
[0171] FIG. 34 is a partial perspective view of a rotor assembly
3400 in which counterbalanced seal assembly 3300 (FIG. 33) is
installed. Rotor assembly 3400 includes a rotor arm 3402, a front
ring plate 3404 (broadly, a first ring plate), and a rear ring
plate 3406 (broadly, a second ring plate). In use, rotor assembly
3400 is mounted for rotation within a rotary device housing, such
as housing 200 (FIG. 2) or housing 2300 (FIG. 23), and enclosed
within the housing by face plates, such as front plate 230 and rear
plate 232 (FIG. 2). Rotor assembly 3400 functions in substantially
the same manner as rotor assembly 300 (FIGS. 2 and 3) described
above.
[0172] As noted above, end seals 3308 facilitate maintaining a seal
around ends 3032, 3034 of seal 3302 at relatively low temperatures.
Specifically, in rotary devices that undergo relatively large
temperature fluctuations during operation, such as rotary
combustion engines, seal 3302 is "undersized" to permit thermal
expansion of seal 3302 in an axial direction. As a result, ends
3032, 3034 of seal 3302 are spaced from the face plates enclosing
rotor assembly 3400 at relatively low temperatures, and seal 3302
does not sealingly engage the face plates.
[0173] End seals 3308 maintain a seal around ends 3032, 3034 of
seal 3302 by sealingly engaging the face plates enclosing rotor
assembly 3400. Specifically, sealing end 3314 of each end seal 3308
is biased against a respective face plate by the biasing member
disposed between end seals 3308, thereby forming a seal at each end
3032, 3034 of seal 3302. As the temperature of rotor assembly 3400
increases, seal 3302 expands in an axial direction until ends 3032,
3034 of seal 3302 sealingly engage the face plates enclosing rotor
assembly 3400. End seals 3308 likewise undergo thermal expansion,
causing non-sealing ends 3316 to expand towards one another,
compressing the biasing member disposed between end seals 3308.
[0174] FIG. 35 is an exploded view of another embodiment of a
counterbalanced seal assembly 3500 suitable for use in a rotary
device, such as rotary engine 100 (FIGS. 1 and 2) and compressor
800 (FIG. 20). FIG. 36 is an end view of counterbalanced seal
assembly 3500. As shown in FIGS. 35 and 36, counterbalanced seal
assembly 3500 includes a crossover or apex seal 3502, a base 3504,
a pair of counterweight mechanisms 3506, a pair of end seals 3508,
and a pair of axially extending pins 3510. In the embodiment
illustrated in FIGS. 35 and 36, counterweight mechanisms 3506 are
hingedly coupled to seal 3502 by pins 3510, as described in more
detail below.
[0175] In the illustrated embodiment, seal 3502 has a generally
T-shaped cross-section, and includes a head 3512 and a stem 3514
extending generally perpendicular from head 3512. Head 3512 defines
a radial outer surface 3516 of seal 3502, and stem 3514 defines a
radial inner surface 3518 of seal 3502. In operation, radial outer
surface 3516 sealingly engages the inner wall or surface of a
rotary device housing, such as housing 200 (FIGS. 1 and 2) or
housing 2300 (FIG. 23).
[0176] Seal 3502 extends in an axial or longitudinal direction,
indicated by arrow 3520 in FIG. 35, from a first end 3522 of seal
3502 to a second end 3524 of seal 3502. First end 3522 and second
end 3524 of seal 3502 each have an end groove 3526 defined therein.
Each end groove 3526 extends axially inward into seal 3502 from one
of first end 3522 and second end 3524, and extends radially into
seal 3502 from radial outer surface 3516. Each end groove 3526 is
sized and shaped to receive at least a portion of one of end seals
3508.
[0177] Seal 3502 also has a pin hole 3528 defined therein extending
axially through seal 3502 from first end 3522 to second end 3524.
Pin hole 3528 is sized and shaped to receive pins 3510 therein.
Seal 3502 may include a single, continuous pin hole, or seal 3502
may include two or more separate pin holes. In the illustrated
embodiment, pin hole 3528 adjoins end grooves 3526 along first end
3522 and second end 3524 of seal 3502, forming a single, continuous
groove. In other embodiments, pin hole 3528 may be separated from
end grooves 3526.
[0178] In the illustrated embodiment, seal 3502 has a pair of
notches 3530 defined therein. Each notch 3530 extends radially into
seal 3502 from radial inner surface 3518, and is sized and shaped
to receive a portion of counterweight mechanism 3506. Notches 3530
are spaced apart from one another in longitudinal direction 3520.
As shown in FIG. 35, notches 3530 separate pin hole 3528 into three
segments, including axial outer segments and an axial inner
segment. In some embodiments, seal 3502 may not include notches
3530.
[0179] In the illustrated embodiment, seal 3502 has a unitary
construction. That is, seal 3502 is formed from a single piece of
material, such as ductile iron. In other embodiments, seal 3502 may
have a modular construction. That is, seal 3502 may include
multiple sealing members similar to seal 2420 (FIGS. 25-27).
[0180] As shown in FIG. 36, base 3504 includes a pair of opposing
sidewalls 3532, 3534, a radial inner wall 3536 extending between
and interconnecting sidewalls 3532, 3534 and a pair of ledges 3538
each extending outward from a respective sidewall 3532, 3534. Base
3504 is configured to be slidably received within a seal assembly
channel, such as seal assembly channel 3018 (FIG. 31). Ledges 3538
are spaced from one another in a circumferential or transverse
direction, and partially define a seal channel 3540 configured to
receive seal 3502, in particular, stem 3514 of seal 3502
therein.
[0181] Base 3504 also includes a pair of fulcrums 3542, each
configured to pivotally engage one of counterweight mechanisms
3506. Each fulcrum 3542 defines a pivot axis about which
counterweight mechanisms 3506 pivot in response to rotation of the
rotor in which counterbalanced seal assembly 3500 is installed. In
the illustrated embodiment, each pivot axis is substantially
parallel to axial direction 3520. In the illustrated embodiment,
each fulcrum 3542 includes a support 3544 extending radially inward
from a respective ledge 3538 towards radial inner wall 3536 of base
3504.
[0182] Base 3504 also has a pair of counterweight channels 3546
defined therein, each configured to receive a portion of
counterweight mechanism 3506 therein. Each counterweight channel
3546 is defined by radial inner wall 3536, a respective sidewall
3532, 3534, a respective ledge 3538, and a respective support 3544.
As shown in FIG. 36, supports 3544 extend radially inward towards
radial inner wall 3536 a sufficient distance to inhibit
counterweight mechanisms 3506 from sliding out of counterweight
channels 3546 in a direction transverse to longitudinal direction
3520.
[0183] In the illustrated embodiment, base 3504 is constructed from
aluminum, although base 3504 may be constructed from any suitable
materials that enable counterbalanced seal assembly 3500 to
function as described herein.
[0184] As shown in FIG. 35, each counterweight mechanism 3506
includes a counterweight 3548, a first lever 3550, and a second
lever 3552. Counterweight 3548 has a generally oblong shape, and is
sized to be received within one of counterweight channels 3546. In
other embodiments, counterweight 3548 may be shaped other than
generally oblong. First lever 3550 and second lever 3552 each
extend away from counterweight 3548, and are spaced from one
another in axial direction 3520. First lever 3550 and second lever
3552 are each sized and shaped to be received within one of notches
3530 defined in seal 3502. Each of first lever 3550 and second
lever 3552 defines an axially extending groove 3554 configured to
cooperate with a respective fulcrum 3542 to cause counterweight
mechanism 3506 to pivot in response to rotation of the rotor in
which counterbalanced seal assembly 3500 is installed. In other
words, each counterweight mechanism 3506 is pivotally coupled to
base 3504 via one of fulcrums 3542.
[0185] First lever 3550 and second lever 3552 each include a
respective pin hole 3556 defined therein. Pin holes 3556 are each
sized and shaped to receive one of pins 3510 therein to hingedly
couple counterweight mechanisms 3506 to seal 3502. More
specifically, when counterbalanced seal assembly 3500 is assembled,
pin holes 3556 are aligned with pin hole 3528 in seal 3502, and
each pin 3510 is inserted through pin hole 3528 and pin hole 3556
defined in one of first lever 3550 and second lever 3552. First
lever 3550 and second lever 3552 thereby engage seal 3502 via pins
3510.
[0186] First lever 3550 and second lever 3552 are spaced from one
another by a distance equal to or greater than the axial distance
between notches 3530 such that first lever 3550 is positioned
within one of notches 3530 and second lever 3552 is positioned
within the other of notches 3530 when counterbalanced seal assembly
3500 is assembled. In the illustrated embodiment, first lever 3550
and second lever 3552 are spaced from one another by a distance
greater than the axial distance between notches 3530. More
particularly, first lever 3550 and second lever 3552 are spaced
from one another such that, when counterbalanced seal assembly 3500
is assembled, the relative axial position of first lever 3550 and
second lever 3552 on each counterweight mechanism 3506 alternates.
That is, when counterbalanced seal assembly 3500 is assembled,
first lever 3550 of one counterweight mechanism 3506 is positioned
axially inward of first lever 3550 of the other counterweight
mechanism 3506, and second lever 3552 of the one counterweight
mechanism 3506 is positioned axially outward of second lever 3552
of the other counterweight mechanism 3506. In other embodiments,
the axial spacing between first lever 3550 and second lever 3552 of
one counterweight mechanism 3506 may be less than the axial spacing
between first lever 3550 and second lever 3552 of the other
counterweight mechanism 3506 such that both levers 3550, 3552 of
one counterweight mechanism 3506 are positioned axially inward of
both levers 3550, 3552 of the other counterweight mechanism 3506.
In yet other embodiments, seal 3502 may not include notches 3530,
and first lever 3550 and second lever 3552 may be positioned
adjacent a respective end 3522, 3524 of seal 3502 when
counterbalanced seal assembly 3500 is assembled.
[0187] End seals 3508 operate in substantially the same manner as
end seals 3308 described above with reference to FIGS. 33 and 34.
In particular, each end seal 3502 is disposed within one of end
grooves 3526, and is configured to form a seal around one of ends
3522, 3524 of seal 3502 and facilitate maintaining the seal at
relatively low temperatures. A biasing member, such as a coil
spring, is positioned within pin hole 3528 between pins 3510 to
bias end seals 3508 towards a respective face plate, such as front
plate 230 or rear plate 232 (FIG. 2), of the rotary device in which
counterbalanced seal assembly 3500 is installed.
[0188] Each pin 3510 is sized and shaped to be received within pin
hole 3528 defined in seal 3502 and at least one of pin holes 3556
defined in first lever 3550 and second lever 3552. Each pin 3510
has a sufficient length in axial direction 3520 to hingedly couple
one of first lever 3550 and second lever 3552 to seal 3502. In
particular, each pin 3510 has a length in axial direction 3520 such
that, when counterbalanced seal assembly 3500 is assembled, pin
3510 extends through pin hole 3528 in seal 3502 and pin hole 3556
defined in one of first lever 3550 and second lever 3552. In the
illustrated embodiment, each pin 3510 has a length in axial
direction such that pin 3510 extends through pin hole 3528 in seal
3502, through pin hole 3556 defined in one of first lever 3550 and
second lever 3552, and back into pin hole 3528 defined in seal
3502.
[0189] The illustrated embodiment includes two pins 3510, each
configured to be inserted in a respective end 3522, 3524 of seal
3502 to hingedly couple counterweight mechanisms 3506 to seal 3502.
In particular, each pin 3510 is formed integrally with one of end
seals 3508. Counterbalanced seal assembly 3500 thus has a reduced
part count as compared to a counterbalanced seal assembly having
pins formed separately from end seals. In other embodiments, pins
3510 may be formed separately from end seals 3508. In one
embodiment, for example, end seals 3508 are omitted from
counterbalanced seal assembly 3500, and counterbalanced seal
assembly 3500 includes discrete pins. In yet other embodiments,
counterbalanced seal assembly 3500 may include a single pin
configured to extend through pin holes 3556 defined in both first
lever 3550 and second lever 3552 when counterbalanced seal assembly
3500 is assembled.
[0190] In use, counterbalanced seal assembly 3500 is installed in a
rotor arm of a rotor, such as rotor arm 3000 (FIG. 30). As rotor
arm 3000 rotates, centrifugal forces acting on counterweight
mechanism 3506 cause counterweight mechanism 3506 to pivot about a
pivot point (e.g., fulcrum 3542). The engagement between levers
3550, 3552 and seal 3502 via pins 3510 limits the radial outward
displacement of seal 3502 resulting from rotation of rotor arm
3000, thereby limiting the contact pressure between seal 3502 and
the inner wall or surface of a rotary device housing, such as
housing 200 (FIGS. 1 and 2) or housing 2300 (FIG. 23).
[0191] The hinged connection between seal 3502 and counterweight
mechanisms 3506 is not limited to the embodiment illustrated in
FIGS. 35 and 36, and may be utilized in other counterbalanced seal
assemblies described herein. In one embodiment, for example, seal
3502 and counterweight mechanism 3506 of counterbalanced seal
assembly 3500 may be utilized in rotor arm 2408 of rotor 2400
(FIGS. 24 and 25), with fulcrum 2448 defining the pivot point about
which counterweight mechanisms 3506 pivot.
[0192] As compared to some known rotary engine systems, the rotary
engines disclosed herein facilitate improving the reliability and
service life of crossover seals within the rotary engine. In
particular, the rotary engines disclosed herein include
counterbalanced seal assemblies that include a seal and a
counterweight mechanism configured to control radial displacement
of the seal. By controlling radial displacement of the seal, the
counterweight mechanism controls the contact pressure between the
seal and an inner wall of a housing that houses the rotary engine,
and counteracts centrifugal forces imparted on the seal from
rotation of the rotor within the rotary engine.
[0193] Additionally, in some embodiments, the counterbalanced seal
assemblies disclosed herein include a control mechanism configured
to apply a variable radial force to the seal to control the contact
pressure between the seal and the inner wall of the rotary engine
housing. The control mechanism can be utilized to selectively vary
the radial force applied to the seal at specified times and/or
rotational positions during a single stroke or revolution of the
rotor, thereby enabling various engine functions, such as
turbocharging, supercharging, and chamber coupling and de-coupling.
Further, by enabling selective control of the radial force applied
to the seal, the control mechanism enables "on the fly" adjustments
to rotary engine operation. For example, the control mechanism can
be utilized to lower the compression ratio of a rotary engine in a
vehicle while operating at freeway cruising speeds to increase fuel
efficiency. The control mechanism may also be utilized to increase
the compression ratio of a rotary engine when additional power is
needed. The control mechanism also permits a rotary engine to run
on different types of fuel by enabling selective adjustment of
compression ratios within the rotary engine.
[0194] Additionally, in some embodiments, the configuration of the
counterbalanced seal assemblies disclosed herein facilitates
installation, removal, and replacement of the counterbalanced seal
assemblies. In particular, the seal and counterweight mechanisms of
some counterbalanced seal assemblies disclosed herein are coupled
to a common structure, such as a base, that enables all components
of the counterbalanced seal assembly to be moved together as a
single unit or module.
[0195] Although specific features of various embodiments of the
invention may be shown in some drawings and not in others, this is
for convenience only. In accordance with the principles of the
invention, any feature of a drawing may be referenced and/or
claimed in combination with any feature of any other drawing.
[0196] This written description uses examples to disclose the
invention, including the best mode, and also to enable any person
skilled in the art to practice the invention, including making and
using any devices or systems and performing any incorporated
methods. The patentable scope of the invention is defined by the
claims, and may include other examples that occur to those skilled
in the art. Such other examples are intended to be within the scope
of the claims if they have structural elements that do not differ
from the literal language of the claims, or if they include
equivalent structural elements with insubstantial differences from
the literal language of the claims.
* * * * *