Clip-Attached Raceway for Variable Compression Engine
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Solution Overview
Problem
Current methods for fixing raceways on variable compression ratio engines, such as electron beam welding and other traditional welding techniques, face issues with insufficient fatigue resistance, thermal deformation, and complexity, leading to potential engine deterioration or destruction, especially under high loads.
Innovation Solution
A clip-fixing raceway system that attaches to the toothed wheel without welding, allowing for any machining process to finish the teeth, is removable, and can be made from different materials with distinct surface treatments, ensuring robust attachment and maintaining the wheel's diameter and geometric integrity, while positioning the contact surface close to the pitch circle for optimal efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electron beam welding or traditional welding techniques are used to fix raceways on the toothed wheel, then the raceways can be attached to the wheel, but the attachment has insufficient fatigue resistance and causes thermal deformation
Solution Approach 1:
The raceway is divided into modular segments that can be independently attached to the toothed wheel using clips. This segmentation allows each segment to be securely fastened without requiring high-energy welding processes, thereby maintaining fatigue resistance while achieving strong attachment. The modular design enables precise positioning and reduces thermal impact on the overall structure.
Solution Approach 2:
Clips are introduced as intermediary elements between the raceway segments and the toothed wheel. These clips provide a mechanical fastening solution that avoids direct welding contact, eliminating thermal deformation while ensuring reliable attachment with sufficient fatigue resistance. The clips act as a mediator that transfers loads without requiring high-temperature joining processes.
2Strength
If welding processes are used to attach raceways, then attachment is achieved, but the process is complex and time-consuming
Solution Approach 1:
The raceway is segmented into multiple attachable sections with standardized clip interfaces. This segmentation transforms a complex welding operation into simpler, repetitive mechanical fastening operations. Each segment can be independently positioned and secured, reducing overall process complexity and manufacturing time while maintaining attachment strength.
Solution Approach 2:
The clip mechanism serves as an intermediary that simplifies the attachment process. Instead of requiring complex welding equipment and procedures, the clips provide a straightforward mechanical fastening system that is easier to implement, control, and inspect, thereby reducing device and process complexity.
3Strength
If welding is used to fix raceways, then attachment is achieved, but thermal deformation occurs affecting the wheel's geometric integrity
Solution Approach 1:
Clips are used as intermediary fastening elements that completely eliminate thermal contact between the raceway and the toothed wheel. This mechanical fastening approach preserves the wheel's original geometric integrity by avoiding thermal deformation, while still achieving sufficient attachment strength through the clip-raceway-wheel connection system.
Solution Approach 2:
The welding process (thermal-mechanical system) is replaced with a mechanical clip fastening system. This substitution eliminates thermal effects that cause geometric deformation, while the mechanical clips provide adequate attachment strength through friction, interference fit, or locking mechanisms designed into the clip structure.
4Stability of the object's composition
If raceways are integrated into the toothed wheel material, then rigidity is reinforced, but usual manufacturing processes like hob or grinding wheel cannot be used
Solution Approach 1:
The raceway is segmented and attached separately from the toothed wheel body. This segmentation allows the toothed wheel to be manufactured using conventional processes like hobbing or grinding wheel machining, while the raceway segments are manufactured and attached independently. The clip fastening system maintains structural rigidity by securely fixing the segments without interfering with standard manufacturing operations.
Solution Approach 2:
The clip fastening system acts as an intermediary that enables the separation of the raceway from the toothed wheel manufacturing processes. This allows each component to be optimized and manufactured independently using appropriate processes, with the clips providing the connection that maintains overall structural rigidity while preserving manufacturing flexibility.
5Ease of manufacture
If the contact surface is positioned away from the pitch circle, then manufacturing is easier, but friction increases and mechanical efficiency decreases
Solution Approach 1:
The position of the contact surface is optimized as a critical parameter. By positioning the contact surface close to the pitch circle through precise raceway segment design and clip placement, the system minimizes friction losses and maximizes mechanical efficiency. This parameter optimization balances manufacturing considerations with performance requirements, ensuring that the slight additional positioning effort yields significant energy efficiency improvements.
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a travel track (50) having a clip attachment (55) for a variable compression ratio engine (10), including at least one curved segment (51), the outer surface (52) of which engages with a travel track provided on the transmission member (3) or on the control member (7) of the variable compression ratio engine (10) and the inner surface (53) of which is kept in contact with an outer curved surface (54) provided on the toothed wheel (5) of said engine, and at least one clip (55) that is provided on at least one of the ends of the curved segment (51) and is attached to one or the other end of the outer curved surface (54), provided on the toothed wheel (5), by coupling with a hook shape (56) or a projection (56) that comprises said wheel (5) near said end of the curved outer surface (54), said hook shape or projection being complementary to that of the clip (55) such as to be able to engage with said clip.