Cylinder Block Attachment Flange for Engine Layout Adaptability
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Solution Overview
Problem
Existing cylinder blocks for engines are not adaptable for both front-engine rear-wheel drive (FR) and front-engine front-wheel drive (FF) layouts without increasing manufacturing costs, as they require alterations in transmission, transaxle, starter motor, and driveshaft designs.
Innovation Solution
A cylinder block with an attachment flange that includes a first flange for longitudinal alignment with the transmission and a second flange for transverse alignment with the transaxle, allowing the same raw material to be used for both FR and FF layouts by cutting off the first flange to adapt for transverse mounting, with integrated ribs and bosses for enhanced rigidity and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single flange design is used for both FR and FF layouts, then manufacturing cost is reduced, but the flange must include unnecessary portions for one layout that increase complexity
Solution Approach 1:
The flange is divided into multiple segments (first flange and second flange) that can be selectively removed. The first flange is designed for FR layout while the second flange is designed for FF layout, allowing the cylinder block to be adapted to different vehicle configurations by removing the unnecessary flange segment, thus reducing complexity while maintaining manufacturing efficiency
Solution Approach 2:
The flange is designed with multi-functionality to serve both FR and FF layouts. By incorporating both first and second flanges with different configurations in a single component, the cylinder block can be universally used across different vehicle types, reducing the need for separate dedicated flange designs and thereby lowering manufacturing costs
2Adaptability or versatility
If the first flange is removed to adapt for FF layout, then adaptability is improved, but additional machining steps are required
Solution Approach 1:
The flange segments are pre-designed and pre-positioned during the initial manufacturing process. The first and second flanges are cast or formed as integral parts of the cylinder block from the beginning, so that when adaptation to FF layout is needed, only a simple removal operation is required rather than complex machining, thus improving adaptability while minimizing additional manufacturing steps
Data Source
AI summary
A cylinder block that can be used commonly in a longitudinally mounted engine and a transversely mounted engine without increasing a manufacturing cost. The cylinder block comprises an attachment flange joined to a transmission or a transaxle, and an oil pan or the oil pan and a ladder frame are attached to a lower end thereof. The attachment flange comprises: a first flange formed on an outer periphery thereof; a first joint surface formed on the first flange to be joined to a matching surface of the transmission; a second flange extending in the inner side of the first flange; and a second joint surface formed on the second flange to be joined to a matching surface of the transaxle.