U.S. patent number 10,385,970 [Application Number 15/195,796] was granted by the patent office on 2019-08-20 for bearing interface with recesses to reduce friction.
This patent grant is currently assigned to Ford Global Technologies, LLC. The grantee listed for this patent is Ford Global Technologies, LLC. Invention is credited to Andrew Vernon Olver, Ian Graham Pegg, Thomas Reddyhoff, Sorin-Cristian Vladescu.
United States Patent |
10,385,970 |
Pegg , et al. |
August 20, 2019 |
Bearing interface with recesses to reduce friction
Abstract
A bearing interface of an apparatus, the apparatus having a
first element and a second element configured to move relative to
each other during operation of the apparatus, the first element
comprising a first bearing surface configured to engage at least a
portion of a second bearing surface of the second element thereby
defining a contact zone between the first bearing surface and the
second bearing surface, the first bearing surface having at least
one recess indented into the first bearing surface, wherein the
dimension of the recess in the direction of movement of the second
element relative to the first element is less than the dimension of
the contact zone in the direction of movement of the second
element.
Inventors: |
Pegg; Ian Graham (Chelmsford,
GB), Vladescu; Sorin-Cristian (London, GB),
Olver; Andrew Vernon (Reading, GB), Reddyhoff;
Thomas (London, GB) |
Applicant: |
Name |
City |
State |
Country |
Type |
Ford Global Technologies, LLC |
Dearborn |
MI |
US |
|
|
Assignee: |
Ford Global Technologies, LLC
(Dearborn, MI)
|
Family
ID: |
54013779 |
Appl.
No.: |
15/195,796 |
Filed: |
June 28, 2016 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20170009886 A1 |
Jan 12, 2017 |
|
Foreign Application Priority Data
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|
|
|
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Jul 10, 2015 [GB] |
|
|
1512115.5 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16J
10/04 (20130101); F16J 9/12 (20130101) |
Current International
Class: |
F16J
9/12 (20060101); F16J 10/04 (20060101) |
References Cited
[Referenced By]
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Other References
Examination Report of Great Britain Patent Application No.
1610544.7, dated Nov. 25, 2016, United Kingdom Intellectual
Property Office, 5 pages. cited by applicant .
Pegg, Ian Graham, "Piston Ring Configured to Reduce Friction," U.S.
Appl. No. 15/194,151, filed Jun. 27, 2016, 32 pages. cited by
applicant .
Pegg, Ian Graham, "Machine with Reduced Cylinder Friction," U.S.
Appl. No. 15/196,587, filed Jun. 29, 2016, 42 pages. cited by
applicant .
Intellectual Property Office of the United Kingdom, Combined Search
and Examination Report of GB1512115.5, dated Jan. 8, 2016, 6 pages.
cited by applicant.
|
Primary Examiner: Amick; Jacob M
Assistant Examiner: Brauch; Charles
Attorney, Agent or Firm: Voutyras; Julia McCoy Russell
LLP
Claims
The invention claimed is:
1. A bearing interface of an apparatus, the apparatus having a
first element and a second element configured to move relative to
each other during operation of the apparatus, the first element
comprising a first bearing surface configured to engage at least a
portion of a second bearing surface of the second element, thereby
defining a contact zone between the first bearing surface and the
second bearing surface, the first bearing surface having at least a
first recess and a second recess indented into the first bearing
surface, a dimension of the first recess and the second recess in a
direction of movement of the second element relative to the first
element being less than a dimension of the contact zone in the
direction of movement of the second element, and wherein the first
recess comprises a first shape and the second recess comprises a
second shape different than the first shape.
2. The bearing interface according to claim 1, wherein the first
bearing surface and at least the portion of the second bearing
surface are parallel in the contact zone during operation of the
apparatus, wherein the second bearing surface is configured to
deform elastically upon engagement with the first bearing surface,
the dimension of the contact zone in the direction of movement of
the second element being defined by a dimension of the elastically
deformed portion of the second bearing surface in the direction of
movement of the second element.
3. The bearing interface according to claim 2, wherein the
dimension of the first recess and the second recess in the
direction of movement of the second element is less than the
dimension of the elastically deformed portion of the second bearing
surface in the direction of movement of the second element.
4. The bearing interface according to claim 1, wherein a film of
lubricant is provided in the contact zone between the first bearing
surface and the second bearing surface during operation of the
apparatus, the film of lubricant having a film thickness that is
substantially constant in the direction of movement of the second
element during operation of the apparatus.
5. The bearing interface according to claim 4, wherein the
dimension of the first recess and the second recess in the
direction of movement of the second element is less than a
dimension of the film of lubricant in the direction of movement of
the second element, wherein the first and second recesses are
configured to trap lubricant and increase locally the thickness of
the film of lubricant in the contact zone.
6. A machine comprising a bearing interface, the machine comprising
an apparatus having a piston cylinder and a piston ring configured
to move relative to each other during operation of the apparatus,
the piston cylinder comprising an inner surface configured to
engage at least a portion of a circumferential surface of the
piston ring, thereby defining a contact zone between the inner
surface of the piston cylinder and the circumferential surface of
the piston ring, the inner surface of the piston cylinder
comprising a top region having a first plurality of recesses
indented into the inner surface of the piston cylinder, wherein the
top region extends towards a bottom end of the inner surface of the
piston cylinder away from a contact zone between a top piston ring
and the inner surface of the piston cylinder when the piston is at
top dead center of a stroke, wherein a dimension of each of the
plurality of recesses in a direction of movement of the piston ring
relative to the piston cylinder is less than a dimension of the
contact zone in the direction of movement of the piston ring.
7. The machine according to claim 6, wherein the inner surface
further comprises: a bottom region having a second plurality of
recesses indented into the inner surface of the piston cylinder,
wherein the bottom region extends towards a top end of the piston
cylinder away from a contact zone between a bottom piston ring and
the inner surface of the piston cylinder when the piston is at
bottom dead center of the stroke of the piston.
8. The machine according to claim 7, wherein the top region and the
bottom region are separated by a middle region having no recesses
indented into the inner surface of the piston cylinder, wherein the
top region and the bottom region are spaced apart in a direction of
travel of the piston.
9. The machine according to claim 7, wherein the top region is
offset from the contact zone between the top piston ring and the
inner surface of the piston cylinder when the piston is at top dead
center of a stroke, and wherein the bottom region is offset from
the contact zone between the bottom piston ring and the inner
surface of the piston cylinder when the piston is at bottom dead
center of the stroke.
10. The machine according to claim 7, wherein the contact zone
between the top piston ring and the inner surface of the piston
cylinder comprises a region bounded by a circumferential contact
between a top edge of the top piston ring and the inner surface of
the piston cylinder, and a bottom edge of the top piston ring and
the inner surface of the piston cylinder when the piston is at top
dead center of the stroke.
11. The machine according to claim 7, wherein the contact zone
between the bottom piston ring and the inner surface of the piston
cylinder comprises a region bounded by a circumferential contact
between a top edge of the bottom piston ring and the inner surface
of the piston cylinder, and a bottom edge of the bottom piston ring
and the inner surface of the piston cylinder when the piston is at
top dead center of the stroke.
12. The machine according to claim 10, wherein the top region
extends from the top edge of the top piston ring when the piston is
at top dead center of the stroke.
13. The machine according to claim 10, wherein the top region
extends from the bottom edge of the top piston ring when the piston
is at top dead center of the stroke.
14. The machine according to claim 10, wherein the top region
extends from in between the top and bottom edges of the top piston
ring when the piston is at top dead center of the stroke.
15. The machine according to claim 11, wherein the bottom region
extends from the top edge of the bottom piston ring when the piston
is at bottom dead center of the stroke.
16. The machine according to claim 11, wherein the bottom region
extends from the bottom edge of the bottom piston ring when the
piston is at bottom dead center of the stroke.
17. The machine according to claim 11, wherein the bottom region
extends from in between the bottom and top edges of the bottom
piston ring when the piston is at bottom dead center of the
stroke.
18. The machine according to claim 7, wherein the top region and
the bottom region extend towards each other, wherein the machine is
an engine or a compressor, and wherein the first and second
pluralities of recesses are provided in a bore of a cylinder block
or in a bore of a cylinder liner.
19. An apparatus, comprising: a bearing interface with a first
bearing surface engaging a second bearing surface, thereby defining
a contact zone therebetween, the first bearing surface having at
least one recess comprising a square-bottomed pocket indented into
the first bearing surface, a dimension of the recess in a direction
of movement of the second bearing surface relative to the first
bearing surface being less than a dimension of the contact zone in
the direction of movement of the second bearing surface.
Description
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to Great Britain Patent
Application No. 1512115.5, filed Jul. 10, 2015, the entire contents
of which are hereby incorporated by reference for all purposes.
FIELD
This disclosure relates to a bearing interface having a plurality
of recesses indented into a bearing surface of the bearing
interface, and in particular, but not exclusively, relates to a
bearing interface in a machine, the machine having a plurality of
recesses provided only in predetermined regions of the bearing
surface of the bearing interface.
The machine may comprise a linear actuator or a rotary machine. The
term "rotary machine" is intended to encompass reciprocating
machines such as internal combustion engines, compressors and
vacuum pumps, as well as machines with rotating components but no
reciprocating parts.
INTRODUCTION
An internal combustion engine typically has one or more
reciprocating pistons which are lubricated to reduce the friction
as the piston slides within a cylinder bore. Lubricated sliding
contacts, such as between the piston rings of a piston and an inner
surface of the cylinder bore, have frictional losses due to the
shear forces generated in the lubricant, contact between surface
asperities, and boundary contacts caused by additives in the
lubricant.
It is desirable to reduce the friction between the piston rings and
the inner surface of the cylinder in order to increase the
efficiency of the engine and reduce wear between engine components.
The friction between the components may be determined by a number
of factors, which include the operational parameters of the engine
and the configuration of each of the sliding surfaces. For example,
the frictional coefficient between sliding components may be
determined using the Stribeck curve, which is used to categorize
the frictional properties between two surfaces as a function of the
viscosity of the lubricant and the relative speed between the
components per unit load. As such, friction may be minimized by
operating at the minimum point on the Stribeck curve, which defines
the transition between hydrodynamic lubrication and mixed
lubrication. However, it is difficult to maintain operation at the
minimum point on the Stribeck curve across the full piston stroke
as a result of the low relative speed between the piston and the
cylinder at the extremes of the range of movement of the
piston.
SUMMARY
According to an aspect of the present disclosure there is provided
a bearing interface of an apparatus, for example a machine such as
an engine, a compressor, a vacuum pump or a gear box. The apparatus
may comprise any type of machine having the bearing interface. The
apparatus has a first element and a second element. The first
element may be configured to move, for example slide and/or rotate,
relative to the second element during operation of the apparatus.
The second element may be configured to move, for example slide
and/or rotate, relative to the first element during operation of
the apparatus. The first element may be fixed, for example
stationary, relative to the second element during operation of the
apparatus. The second element may be fixed, for example stationary,
relative to the first element during operation of the apparatus.
The first element comprises a first bearing surface. The second
element comprises a second bearing surface. The first and second
bearing surfaces are configured to engage each other. The term
`engage` is intended to encompass two surfaces which are separated
by a thin film of lubricant, as well as surfaces which come into
direct physical contact. The first bearing surface is configured to
engage at least a portion of a second bearing surface. The portion
of the second element that engages the first element defines a
contact zone between the first bearing surface and the second
bearing surface. The first bearing surface has at least one recess,
for example a pocket, indented into the first bearing surface. The
recess may comprise an opening in the first bearing surface. The
dimension of the recess, for example the dimension of the opening
of the recess, in the direction of movement of the second element
relative to the first element is less than the dimension of the
contact zone in the direction of movement of the second
element.
The first bearing surface and at least the portion of the second
bearing surface may be parallel in the contact zone during
operation of the apparatus. The second bearing surface may be
configured to deform elastically upon engagement with the first
bearing surface. The dimension of the contact zone in the direction
of movement of the second element may be defined by the dimension
of the elastically deformed portion of the second bearing surface
in the direction of movement of the second element. The dimension
of the recess in the direction of movement of the second element
may be less than the dimension of the elastically deformed portion
of the second bearing surface in the direction of movement of the
second element.
A lubricant may be used to reduce the friction between the first
and second bearing surfaces. A lubricant film may be provided, for
example formed, in the contact zone between the first bearing
surface and the second bearing surface during operation of the
apparatus. The lubrication regime between the first and second
bearing surfaces may be a hydrodynamic lubrication regime, a mixed
lubrication regime and/or a boundary lubrication regime. The
lubrication regime may transition between the hydrodynamic
lubrication regime, the mixed lubrication regime and/or the
boundary lubrication regime, depending on the operational
parameters of the apparatus. The film of lubricant may have a film
thickness that is substantially constant in the direction of
movement of the second element during operation of the
apparatus.
The dimension of the recess in the direction of movement of the
second element may be less than the dimension of the film of
lubricant in the direction of movement of the second element. The
recesses may be configured to trap lubricant. The recesses may be
configured to increase locally the thickness of the film of
lubricant in the contact zone.
A reciprocating machine, such as an engine or compressor, may be
provided having one or more of the bearing interfaces. The engine
may comprise one or more cylinders and/or one or more engine
pistons. The first element may be an engine cylinder. The first
bearing surface may be an inner surface of the cylinder. The second
element may be a piston ring of the engine piston. The second
bearing surface may be a circumferential surface of the piston
ring. A least a portion of the circumferential surface of the
piston ring may be configured to engage the inner surface of the
cylinder. Each cylinder may have an inner surface configured to
engage at least a portion of a circumferential surface of a piston
ring of an engine piston. The portion of the piston ring that
engages the inner surface may define the contact zone between the
inner surface of the cylinder and the circumferential surface of
the piston ring. The contact zone may have a dimension in the
direction of travel of the piston, for example an axial dimension
that defines the overall length of the contact zone in the
direction of travel of the piston. The inner surface may have at
least one recess indented into the inner surface. The recess may
have a dimension in the direction of travel of the piston, for
example an axial dimension that defines the overall length of the
recess in the direction of travel of the piston. The dimension of
the recess in the direction of travel of the piston may be less
than the dimension of the contact zone in the direction of travel
of the piston.
The inner surface of the cylinder and at least a portion of the
circumferential surface of a piston ring may be parallel in the
contact zone, for example during operation of the engine. The
piston ring and/or the inner surface may be configured to deform
elastically under loading. The portion of the piston ring that
deforms elastically under loading and engages the inner surface of
the cylinder may define an elastic contact zone between the inner
surface of the cylinder and the circumferential surface of the
piston ring. The dimension of the contact zone in the direction of
travel of the piston may be defined by the dimension, for example
the axial length, of the elastically deformed portion of the piston
ring. The circumferential surface of the piston ring and the inner
surface of the cylinder may be parallel as a result of the elastic
deformation of the piston ring and/or the inner surface. The
dimension of the recess in the direction of travel of the piston
may be less than the dimension of the elastically deformed portion
of the piston ring in the direction of travel of the piston.
A lubricant may be used to reduce the friction between the piston
ring and the inner surface of the cylinder. A lubricant film may be
formed in the contact zone between the circumferential surface of
the piston ring and the inner surface of the cylinder during
operation of the engine. The lubricant film in between at least a
portion of the circumferential surface and the inner surface may
have a film thickness that is substantially constant in the
direction of travel of the piston during operation of the engine.
For example, the film thickness of the lubricant film may be
substantially constant where the circumferential surface of the
piston ring and the inner surface of the cylinder are parallel. The
portion of the lubricant film that has a substantially constant
film thickness may have a dimension in the direction of travel of
the piston, for example an axial dimension that defines the overall
length of the portion of the lubricant film that has a
substantially constant film thickness. The dimension of the recess
in the direction of travel of the piston may be less than the
dimension of the portion of the lubricant film that has a
substantially constant film thickness in the direction of travel of
the piston.
The inner surface may comprise a top region having a plurality of
recesses indented into the inner surface. The top region may extend
towards the bottom end of the cylinder away from a contact zone
between a top piston ring and the inner surface when the piston is
at top dead center of a stroke. The inner surface may comprise a
bottom region having a plurality of recesses indented into the
inner surface. The bottom region may extend towards the top end of
the cylinder away from a contact zone between a bottom piston ring
and the inner surface when the piston is at bottom dead center of
the stroke of the piston. The inner surface may be an inner surface
of a bore of a cylinder block. The inner surface may be an inner
surface of a cylinder liner.
The recesses may be configured to retain a fluid, for example each
recess may comprise a pocket configured to trap the fluid in the
inner surface. The recesses may be configured to slow down the rate
at which fluid drains away from the top and/or bottom regions of
the inner surface. The top region and the bottom region may be
separated by a middle region having no recesses indented into the
inner surface. The top region and the bottom region may be spaced
apart, for example by the middle region, in the direction of travel
of the piston.
The top region may comprise a top band of recesses extending around
the full circumference of the inner surface. The bottom region may
comprise a bottom band of recesses extending around the full
circumference of the inner surface. The middle region may comprise
a middle band having no recesses extending around the full
circumference of the inner surface. The top band may have an axial
dimension in the direction of travel of the piston. The bottom band
may have an axial dimension in the direction of travel of the
piston. The middle band may have an axial dimension in the
direction of travel of the piston. The axial dimension of the
middle band may be greater than the axial dimension of the top
and/or bottom bands.
The contact zone between the piston ring and the inner surface of
the cylinder may comprise a region bounded by the circumferential
contact between a top edge of the piston ring and the inner
surface, and a bottom edge of the piston ring and the inner
surface.
The contact zone, for example a top contact zone, between the top
piston ring and the inner surface of the cylinder may comprise a
region bounded by the circumferential contact between a top edge of
the top piston ring and the inner surface, and a bottom edge of the
top piston ring and the inner surface when the piston is at top
dead center of a stroke.
The contact zone, for example a bottom contact zone, between the
bottom piston ring and the inner surface of the cylinder may
comprise a region bounded by the circumferential contact between a
top edge of the bottom piston ring and the inner surface, and a
bottom edge of the bottom piston ring and the inner surface when
the piston is at top dead center of a stroke.
The top region may be offset, for example by a predetermined
distance, from the contact zone between the top piston ring and the
inner surface when the piston is at top dead center of a stroke.
The top region may be offset from the top contact zone towards the
bottom region. The bottom region may be offset, for example by a
predetermined distance, from the contact zone between the bottom
piston ring and the inner surface when the piston is at bottom dead
center of a stroke. The bottom region may be offset from the bottom
contact zone towards the top region.
The top region may extend from the top edge of the top piston ring
when the piston is at top dead center of a stroke. The top region
may extend from the bottom edge of the top piston ring when the
piston is at top dead center of a stroke. The top region may extend
from in between the top and bottom edges of the top piston ring
when the piston is at top dead center of a stroke.
The bottom region may extend from the top edge of the bottom piston
ring when the piston is at bottom dead center of a stroke. The
bottom region may extend from the bottom edge of the bottom piston
ring when the piston is at bottom dead center of a stroke. The
bottom region may extend from in between the bottom and top edges
of the bottom piston ring when the piston is at bottom dead center
of a stroke. The top region and the bottom region may extend
towards each other.
According to another aspect of the present disclosure there is
provided a method of designing, forming and/or manufacturing a
bearing interface of an apparatus, for example a rotary and/or
reciprocating machine such as an engine, a compressor, a vacuum
pump or a gear box. The apparatus may comprise any type of rotary
and/or reciprocating device having the bearing interface. The
apparatus comprises a first element and a second element. The first
element may be configured to move, for example slide and/or rotate,
relative to the second element during operation of the apparatus.
The second element may be configured to move, for example slide
and/or rotate, relative to the first element during operation of
the apparatus. The first element may be fixed, for example
stationary, relative to the second element during operation of the
apparatus. The second element may be fixed, for example stationary,
relative to the first element during operation of the apparatus.
The first element comprises a first bearing surface. The second
element comprises a second bearing surface. The first and second
bearing surfaces are configured to engage each other. The term
`engage` is intended to encompass two surfaces which are separated
by a thin film of lubricant, as well as surfaces which come into
direct physical contact. The first bearing surface is configured to
engage at least a portion of a second bearing surface. The portion
of the second bearing surface that engages the first bearing
surface defines a contact zone between the first bearing surface
and the second bearing surface. The first bearing surface has at
least one recess, for example a pocket, indented into the first
bearing surface. The recess may comprise an opening in the first
bearing surface. The method comprises determining the dimension of
the contact zone in the direction of movement of the second
element. The method comprises designing, forming and/or
manufacturing the recess so that the dimension of the recess in the
direction of movement of the second element is less than the
dimension of the contact zone in the direction of movement of the
second element.
According to an aspect of the present disclosure there is provided
an engine having one or more cylinders. Each cylinder has an inner
surface configured to engage at least a portion of a
circumferential surface of a piston ring of an engine piston. The
portion of the piston ring that engages the inner surface defines a
contact zone between the inner surface of the cylinder and the
circumferential surface of the piston ring. The contact zone has a
dimension in the direction of travel of the piston, for example an
axial dimension that defines the overall length of the contact zone
in the direction of travel of the piston. The inner surface has at
least one recess indented into the inner surface. The recess has a
dimension in the direction of travel of the piston, for example an
axial dimension that defines the overall length of the recess in
the direction of travel of the piston. The dimension of the recess
in the direction of travel of the piston is less than the dimension
of the contact zone in the direction of travel of the piston.
According to another aspect of the present disclosure there is
provided a method of designing an engine, for example an internal
combustion engine. The engine comprises one or more cylinders. Each
cylinder has an inner surface configured to engage at least a
portion of a circumferential surface of a piston ring of an engine
piston. The portion of the piston ring that engages the inner
surface defines a contact zone between the inner surface of the
cylinder and the circumferential surface of the piston ring. The
contact zone has a dimension in the direction of travel of the
piston, for example an axial dimension that defines the overall
length of the contact zone. The inner surface has at least one
recess indented into the inner surface. The method comprises
determining the dimension of the contact zone in the direction of
travel of the piston. The method comprise designing the recess so
that the dimension of the recess in the direction of travel of the
piston is less than the dimension of the contact zone in the
direction of travel of the piston.
According to another aspect of the present disclosure there is
provided an engine having one or more cylinders. Each of the
cylinders has an inner surface configured to engage one or more
piston rings of an engine piston. The inner surface may comprise a
top region having a plurality of recesses indented into the inner
surface. The top region may extend towards the bottom end of the
cylinder away from a contact zone between a top piston ring and the
inner surface when the piston is at top dead center of a stroke.
The inner surface may comprise a bottom region having a plurality
of recesses indented into the inner surface. The bottom region may
extend towards the top end of the cylinder away from a contact zone
between a bottom piston ring and the inner surface when the piston
is at bottom dead center of the stroke of the piston.
According to another aspect of the present disclosure there is
provided a method of manufacturing an engine. The engine comprises
one or more cylinders. Each cylinder has an inner surface
configured to engage one or more piston rings of an engine piston.
The method may comprise providing a plurality of recesses indented
into a top region of the inner surface. The top region may extend
towards the bottom end of the cylinder away from a contact zone
between a top piston ring and the inner surface when the piston is
at top dead center of a stroke. The method may comprise providing a
plurality of recesses indented into a bottom region of the inner
surface. The bottom region may extend towards the top end of the
cylinder away from a contact zone between a bottom piston ring and
the inner surface at bottom dead center of the stroke of the
piston.
To avoid unnecessary duplication of effort and repetition of text
in the specification, certain features are described in relation to
only one or several aspects or arrangements of the disclosure.
However, it is to be understood that, where it is technically
possible, features described in relation to any aspect or
arrangement of the disclosure may also be used with any other
aspect or arrangement of the disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present disclosure, and to show
more clearly how it may be carried into effect, reference will now
be made, by way of example, to the accompanying drawings, in
which:
FIG. 1 shows a partial cross section through an engine;
FIG. 2 shows a detailed view of the piston rings of an engine
piston;
FIG. 3 shows a diagrammatic representation of a fluid film between
a piston ring and an inner surface of a cylinder; and
FIG. 4 shows a cylinder of an engine.
DETAILED DESCRIPTION
FIG. 1 shows a simplified cross-section of an engine 101. The
engine 101 is a four-cylinder engine having an overhead camshaft.
However, the engine 101 may be any type of engine, for example a
single overhead camshaft (SOHC) engine, a double overhead camshaft
(DOHC) engine, an overhead valve (OHV) engine, or other appropriate
type of engine. Whilst the engine 101 shown in FIG. 1 is a
four-cylinder engine, the engine 101 may comprise any appropriate
number of cylinders 103, for example the engine 101 may be a
three-cylinder engine, a six-cylinder engine or an eight-cylinder
engine. The cylinders 103 may be arranged in an appropriate
configuration, such as in-line, horizontally opposed or V-form.
Each of the cylinders 103 comprises an inner surface 105 configured
to engage the piston rings 107 of an engine piston 109. The inner
surface 105 may be an inner surface of a cylinder bore formed
directly into a cylinder block of the engine 101, as shown in FIG.
1. Alternatively, the inner surface 105 may be an inner surface of
a cylinder liner that is assembled into the cylinder block.
During operation of the engine 101, each of the pistons 109
reciprocates within the cylinder 103 between a top dead center
position and a bottom dead center position. In the context of the
present disclosure, the term "top dead center" refers to the
furthest point of a piston's travel, at which it changes from an
upward stroke, i.e. away from a crankshaft of the engine 101, to a
downward stroke, i.e. towards the crankshaft of the engine 101. The
term "bottom dead center" refers to the furthest point of a
piston's travel, at which it changes from a downward to an upward
stroke. In a similar manner, the term "top" end of the cylinder 103
refers to an end of the cylinder 103 at which the piston 109
reaches top dead center, and the term "bottom" end of the cylinder
103 refers to an end of the cylinder 103 at which the piston 109
reaches bottom dead center.
During the operation of the engine 101, the linear speed of the
piston 109 varies between a minimum speed, for example a zero speed
when the piston is stationary relative to cylinder 103 at top dead
center or bottom dead center, and a maximum speed as the piston 109
moves between top center and bottom dead center. As a result of the
change in speed of the piston 109, the coefficient of friction
between the piston rings 107 and the inner surface 105 of the
cylinder varies as the piston 109 travels within the cylinder
bore.
In order to reduce the friction between the sliding components of
the engine 101, such as the piston rings 107 and the inner surface
105 of the cylinder, a lubricant may be used. The frictional
coefficient between sliding components may be determined using the
Stribeck curve, which is used to categorize the frictional
properties between two surfaces as a function of the viscosity of
the lubricant and the relative speed between the components per
unit load. Friction may be minimized by operating at the minimum
point on the Stribeck curve, which defines the tribological
transition between hydrodynamic lubrication and mixed lubrication.
However, it is difficult to maintain operation at the minimum point
on the Stribeck curve across the full piston stroke as a result of
the cyclical acceleration and deceleration of the piston 109. For
example, it is difficult to maintain hydrodynamic lubrication
towards the top and bottom ends of the piston stroke owing to the
low relative speeds between the piston 109 and the cylinder 103. In
particular, at the ends of the travel of the piston 109, where the
piston speed drops to zero, a lubricant film between the piston
rings 107 and the inner surface 105 of the cylinder 103 can
collapse as there is no motion to form a hydrodynamic lubricant
film. The collapse of the film is dependent on how fast the
lubricant can drain away from a contact zone 111 between the piston
rings 107 and the inner surface 105 of the cylinder 103.
FIG. 2 shows a detailed view of the contact zones 111 between the
piston rings 107 and the inner the surface 105 of the cylinder 103.
In the arrangement shown in FIGS. 1 to 3, the piston 109 has a top
piston ring 107A and a bottom piston ring 107B. However, the piston
109 may have any appropriate number of piston rings 107, for
example the piston 109 of FIGS. 1 to 3 has a middle piston ring
107C. Each of the piston rings 107 may be configured to perform a
different function, for example top piston ring 107A may be a
compression ring configured to provide a seal between the top and
bottom of the cylinder 103 on either side of the piston 109, and
the bottom piston ring 107B may be and oil scraper ring configured
to remove oil from the inner surface 105 of the cylinder 103.
In the arrangement shown in FIG. 2, the top and bottom piston rings
107A, 107B each comprise a circumferential surface 117A, 117B
configured to engage the inner surface 105 of the cylinder 103. The
piston rings 107 are axially aligned with the piston 109 such that
the circumferential surfaces 117A, 117B substantially engage the
inner surface 105 of the cylinder 103. In this manner, the contact
zone 111A between the top piston ring 107A and the inner surface
105 of the cylinder 103 is defined by a region bounded by the
circumferential contacts between a top edge 113A of the top piston
ring 107A and the inner surface 105, and a bottom edge 115A of the
top piston ring 107A and the inner surface 105. In a similar
manner, the contact zone 111B between the bottom piston ring 107B
and the inner surface 105 of the cylinder 103 comprises a region
bounded by the circumferential contacts between a top edge 113B of
the bottom piston ring 107B and the inner surface 105, and a bottom
edge 115B of the bottom piston ring 107B and the inner surface 105.
However, in a different arrangement, the piston rings 107 may be
configured such that only a portion of the or each circumferential
surface 117A, 117B engages the inner surface 105 of the cylinder
103. For example the circumferential surfaces 117A, 117B may
comprise one or more ribs/projections that extend at least
partially around the circumference of the piston rings 107. It is
understood therefore that the contact zone 111 between any one of
the piston rings 107 may be defined by the portion of the
circumferential surface of the piston ring 107 that engages the
inner surface 105 of the cylinder 103.
The inner surface 105 of the cylinder 103 comprises a top region
119 located towards the top end of the cylinder 103 and a bottom
region 121 located towards the bottom end of the cylinder 103. Each
of the top and bottom regions 119, 121 may comprise a plurality of
recesses 129 indented into the inner surface 105. The recesses 129
may comprise any type opening in the inner surface 105 that enables
a fluid, such as a lubricant, to be held within the opening as the
piston ring 107 moves over the opening. For example, the recesses
129 may comprise a plurality of pockets shaped to retain lubricant,
and/or decrease the rate at which lubricant drains away from the
contact zones 111. The pockets may be of any shape, for example the
pockets may be square, rectangular, circular or any other shape. In
one arrangement, the pockets may be of a similar shape to each
other. In another arrangement, the plurality of pockets may
comprise a number of differently formed/shaped pockets, for example
the plurality of pockets may comprise a number of round-bottomed
pockets and a number of square-bottomed pockets that are configured
to trap lubricant.
For the pockets to be effective, lubricant needs to be restricted
from "leaking" out of the pocket as the piston ring 107 travels
over it. This can be achieved by having a contact zone 111 that is
larger than an opening 131 of the recess 129 in the direction of
travel of the piston 109. In FIG. 2, each of the piston rings 107
has a circumferential surface that has a straight/flat profile such
that the circumferential surface is substantially parallel to the
inner surface 105 during operation of the engine. In such an
arrangement, the dimension of the contact zone 111 in the direction
of travel of the piston 109 may be defined by the dimension between
the top and bottom edges of the piston ring 107. In order to
prevent the lubricant from leaking out of the pocket, the pocket
may be designed such that the overall dimension 131 of the pocket
in the direction of travel of the piston 109 is less than the
dimension between the top and bottom edge of the piston ring
107.
However, the circumferential surface may have a curved profile, for
example a barreled profile. The dimension of the contact zone 111
in the direction of travel of the piston 109 may be defined by the
size, e.g. axial length, of an elastic contact zone between the
inner surface and a portion of the circumferential surface of the
piston ring 107 that deforms elastically under loading. For
example, the dimension of the contact zone 111 in the direction of
travel of the piston 109 may be defined by a portion of the curved
profile that deforms elastically to provide a portion of the
circumferential surface that is parallel with the inner surface 105
of the cylinder 103. The size of the elastic contact zone may be
dependent upon the radial loading of the piston ring 107 against
the inner surface 105, the shape/form of the circumferential
surface of the piston ring 107, and/or the material properties,
e.g. the Young's modulus, of the respective surfaces. In order to
prevent the lubricant from leaking out of the pocket, the pocket
may be designed such that the overall dimension 131 of the pocket
in the direction of travel of the piston 109 is less than the
dimension of the elastic contact zone in the direction of travel of
the piston.
During operation of the engine, a lubricant film 133 may be formed
between the circumferential surface of the piston ring 107 and the
inner surface 105 of the cylinder 103, for example as a result of
the motion between the respective surfaces. The lubricant film 133
may be used to separate the inner surface 105 and the
circumferential surface of the piston ring 107 so that there is no
physical contact between the two surfaces. FIG. 3 shows a
diagrammatic representation of the lubricant film 133 between the
piston ring 107 and the inner surface 105 of the cylinder 103 as
the piston ring 107 moves relative to the inner surface 105. The
lubricant film 133 has a film thickness that is a function of the
shape of the circumferential surface of the piston ring 107, the
velocity gradient between the piston ring 107 and the inner surface
105, the shear stress in the lubricant, the dynamic viscosity of
the lubricant, and/or the radial loading of the piston ring 107. In
FIG. 3, the thickness of the lubricant film 133 varies between a
maximum thickness in a convergence zone in front of the piston ring
107 and a minimum thickness in a divergence zone behind the piston
ring 107, for example where the film 133 cavitates. As a result,
the hydrodynamic pressure generated in the lubricant film 133
varies as a function of film thickness. FIG. 3 shows the
relationship between film thickness and hydrodynamic pressure.
In FIG. 3, the piston ring 107 is a barreled piston ring having a
curved circumferential surface that deforms elastically under
loading, which results in a portion of the circumferential surface
being parallel with the inner surface 105 of the cylinder 103. As a
result, the lubricant film 133 has a portion 135 of constant film
thickness in the region where the circumferential surface is
parallel with the inner surface 105. In order to prevent the
lubricant from leaking out of the pocket, the pocket may be
designed such that the overall dimension 131 of the pocket in the
direction of travel of the piston 109 is less than the length of
the portion 135 of the lubricant film 133 that has a substantially
constant film thickness, i.e. the length of the portion 135 of the
lubricant film 133 that generates a substantially constant
hydrodynamic pressure. In an arrangement where the hydrodynamic
pressure acts to separate the circumferential surface of the piston
ring 107 from the inner surface 105, the overall dimension of the
contact zone 111 may be determined by the dimension of a high
pressure region of the lubricant film 133 in the direction of
travel of the piston 109. Further, the hydrodynamic pressure may
act to deform elastically a portion of the circumferential surface
of the piston ring 107. The overall dimension of the elastic
contact zone may therefore be a function of the hydrodynamic
pressure generated in the lubricant film 133 and the properties of
the material from which piston ring is manufactured.
By trapping lubricant, it is possible to ensure that the
lubrication regime remains hydrodynamic and prevents contact
between the piston rings 107 and the inner surface 105 of the
cylinder 103, for example in those regions of the inner surface 105
where the speed of the piston 109 approaches zero. However, in
those regions of the inner surface 105 where the speed of the
piston 109 high, for example mid stroke of the piston 109, the
provision of recesses may act to increase the coefficient of
friction as a hydrodynamic film may already be established due to
the high relative speeds between the piston rings 107 and surface
105 of the cylinder 103. It is desirable therefore to provide
recesses in regions of the inner surface 105 only where the
relative speeds between piston rings 107 and the inner surface 105
approach zero, for example where the piston 109 is at top dead
center and bottom dead center of the piston stroke.
FIG. 4 shows a schematic view of the cylinder 103 having the piston
109 in a first position 123 at top dead center and in a second
position 125 at bottom dead center. The top region 119 of the inner
surface 105 extends towards the bottom end of the cylinder 103 away
from the contact zone 111A between the top piston ring 107A and the
inner surface 105 when the piston 109 is at top dead center of a
stroke. In the arrangement shown in FIG. 4, the top region 119
extends from the bottom edge 115A of the top piston ring 107A when
the piston 109 is at top dead center. However, the top region 119
may extend from any portion of the contact zone 111A between the
top piston ring 107A and the inner surface 105 when the piston 109
is at top dead center of a stroke. For example, the top region 119
may extend from the top edge 113A of the top piston ring 107A, or
from any point in between the top and bottom edges 113A, 115A when
the piston 109 is at top dead center. In another arrangement, the
top region 119 may be offset, for example towards the bottom region
121, from the contact zone 111A between the top piston ring 107A
and the inner surface 105 when the piston 109 is at top dead center
of a stroke. It is appreciated therefore that in each of the
above-mentioned arrangements, the top region 119 does not extend
beyond the extent of travel of the top piston ring 107A, and that
the plurality of recesses are not provided beyond the extent of
travel of the top piston ring 107A when the piston 109 is at top
dead center of a stroke.
The bottom region 121 extends towards the top end of the cylinder
103 away from the contact zone 111B between the bottom piston ring
107B and the inner surface 105 when the piston 109 is at bottom
dead center of a stroke. In the arrangement shown in FIG. 4, the
bottom region 121 extends from the top edge 113B of the bottom
piston ring 107B when the piston 109 is at bottom dead center.
However, the bottom region 121 may extend from any portion of the
contact zone 111B between the bottom piston ring 107B and the inner
surface 105 when the piston 109 is at bottom dead center of a
stroke. For example, the bottom region 121 may extend from the
bottom edge 115B of the bottom piston ring 107B, or from any point
in between the top and bottom edges 113B, 115B when the piston 109
is at bottom dead center. In another arrangement, the bottom region
121 may be offset, for example towards the top region 119, from the
contact zone 111B between the bottom piston ring 107B and the inner
surface 105 when the piston 109 is at bottom dead center of a
stroke. It is appreciated therefore that in each of the
above-mentioned arrangements, the bottom region 121 does not extend
beyond the extent of travel of the bottom piston ring 107B, and
that the plurality of recesses are not provided beyond the extent
of travel of the bottom piston ring 107B when the piston 109 is at
bottom dead center of a stroke.
The inner surface 105 of the cylinder 103 may comprise a middle
region 127 in between the top and bottom regions 119, 121. The
middle region 127 may be proximate to the top and bottom regions
119, 121, or may be spaced apart and separate from the top and
bottom regions 119, 121. The middle region 127 may provide a region
of the inner surface that has no recesses configured to trap fluid,
for example the middle region 127 of the inner surface 105 may be a
smooth surface that separates the top and bottom regions 119, 121.
The middle region may be provided across the majority of the inner
surface 105, with the top and bottom regions being provided towards
the top and bottom ends of the inner surface. The inner surface 105
of the cylinder 103 may, therefore, be configured to provide
discrete regions 119, 121 that are configured to prevent the
lubrication regime from transitioning into boundary lubrication
from hydrodynamic lubrication in the regions of the piston stroke
where the speed of the piston 109 approaches zero. In this manner,
the coefficient of friction is minimized by maintaining a
lubrication regime that operates near to the minimum of the
Stribeck curve during operation of the engine.
The Figures show example configurations with relative positioning
of the various components. If shown directly contacting each other,
or directly coupled, then such elements may be referred to as
directly contacting or directly coupled, respectively, at least in
one example. Elements described as directly downstream or directly
upstream of one another may be defined herein such that there are
no intervening components between the two comparative elements.
Similarly, elements shown contiguous or adjacent to one another may
be contiguous or adjacent to each other, respectively, at least in
one example. As an example, components laying in face-sharing
contact with each other may be referred to as in face-sharing
contact. As another example, elements positioned apart from each
other with only a space there-between and no other components may
be referred to as such, in at least one example. As yet another
example, elements shown above/below one another, at opposite sides
to one another, or to the left/right of one another may be referred
to as such, relative to one another. Further, as shown in the
figures, a topmost element or point of element may be referred to
as a "top" of the component and a bottommost element or point of
the element may be referred to as a "bottom" of the component, in
at least one example. As used herein, top/bottom, upper/lower,
above/below, may be relative to a vertical axis of the figures and
used to describe positioning of elements of the figures relative to
one another. As such, elements shown above other elements are
positioned vertically above the other elements, in one example. As
yet another example, shapes of the elements depicted within the
figures may be referred to as having those shapes (e.g., such as
being circular, straight, planar, curved, rounded, chamfered,
angled, or the like). Further, elements shown intersecting one
another may be referred to as intersecting elements or intersecting
one another, in at least one example. Further still, an element
shown within another element or shown outside of another element
may be referred as such, in one example.
It will be appreciated by those skilled in the art that although
the invention has been described by way of example with reference
to one or more arrangements, it is not limited to the disclosed
arrangements and that alternative arrangements could be constructed
without departing from the scope of the invention as defined by the
appended claims.
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