Cast Piston Supporting Ribs with Base-Facing Recesses
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Solution Overview
Problem
Internal combustion engine pistons face a trade-off between maximizing structural rigidity and minimizing weight, with increased rigidity leading to higher weight and production costs, and existing cast pistons lack efficient reinforcement methods.
Innovation Solution
A cast piston design featuring supporting ribs within the piston skirt, with recesses facing the piston base to reduce weight and optimize material distribution, integrated with the casting process for enhanced structural rigidity and reduced material consumption, utilizing aluminum for lightweight yet rigid construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If supporting ribs are added to strengthen the piston skirt, then structural rigidity is improved, but weight increases
Solution Approach 1:
The supporting ribs are strategically positioned only in the piston skirt regions experiencing high stresses, rather than uniformly distributing reinforcement throughout the entire piston. This localized strengthening approach provides maximum structural rigidity where needed while minimizing unnecessary material addition in low-stress areas, thereby reducing overall weight increase.
Solution Approach 2:
The piston skirt is divided into multiple regions with different reinforcement requirements. Supporting ribs are segmented and placed specifically at high-stress locations, while other areas maintain thinner walls. This segmentation allows the structure to optimize strength-to-weight ratio by providing reinforcement only where mechanically necessary.
2Weight of moving object
If the piston is made of aluminum to reduce weight, then weight is minimized, but heat resistance becomes insufficient
Solution Approach 1:
The piston employs a composite construction combining aluminum alloy with reinforcing ribs made of stronger material. The aluminum provides lightweight properties while the reinforcing ribs (potentially steel or reinforced polymer) provide enhanced heat resistance and structural strength in critical areas, creating a composite structure that achieves both low weight and high temperature resistance.
3Ease of manufacture
If supporting ribs are integrally formed with the piston skirt, then manufacturing complexity is reduced, but material homogeneity may be compromised
Solution Approach 1:
The supporting ribs are integrated into the piston skirt as a single monolithic component formed in one casting operation. This merging of the ribs with the piston skirt eliminates separate manufacturing steps, reduces assembly complexity, and ensures uniform material distribution throughout the entire structure, thereby achieving both manufacturing simplicity and material homogeneity.
Data Source
AI summary
The invention relates to a cast piston for an internal combustion engine having a piston base, a cylindrical piston head connected to the piston base, and pin bores provided in an at least partially hollow piston shaft, which is positioned on the side of the piston head opposite the piston base. The piston has one or more supporting ribs located at least partially in the piston shaft, and at least one supporting rib has a recess on the side facing the piston base.