Engine Crankcase Firing Deck Anti-Distortion Projections
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Solution Overview
Problem
Conventional engine cylinder blocks experience bore distortion due to uneven stiffness and clamping forces, leading to increased engine oil consumption and combustion leaks, which can result in engine failure, despite conventional reinforcement methods.
Innovation Solution
A firing deck with anti-distortion projections of varying thickness on both the intake and exhaust sides, disposed between bosses and cylinder bores, to enhance structural stiffness and reduce distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the firing deck is reinforced by filling shake-out holes or adding arch-formations on the intake side only, then bore distortion is reduced to some extent, but the gasket sealing pressures decrease at locations between the head bolts due to structural weakness
Solution Approach 1:
The firing deck is designed with non-uniform thickness, featuring thicker regions at specific locations between cylinder bores where gasket sealing pressure is critical, while maintaining uniform thickness in other areas. This local variation in thickness provides enhanced structural support at weak points without compromising overall sealing pressure distribution.
2Strength
If the thickness of the firing deck is increased between cylinder bores to address distortion, then structural stiffness is improved, but the complexity of the firing deck design increases
Solution Approach 1:
Rather than uniformly increasing the entire firing deck thickness, the design incorporates localized thickness variations only in specific regions between cylinder bores where distortion and structural weakness are most pronounced. This targeted approach enhances stiffness where needed while keeping the overall design simple and manufacturable.
3Ease of manufacture
If conventional reinforcement methods are used with uniform thickness firing deck, then manufacturing is simpler, but bore distortion continues to occur due to uneven clamping forces
Solution Approach 1:
The firing deck employs localized thickness variations at critical locations between cylinder bores to counteract uneven clamping forces and prevent bore distortion, while maintaining uniform thickness in non-critical areas to preserve manufacturing simplicity. This selective reinforcement approach balances ease of manufacture with manufacturing precision.
Data Source
AI summary
A firing deck (16) for an engine crankcase includes a firing side surface (35) and a coolant side surface (34). A plurality of cylinder bores (18) are disposed through the firing deck (16) from the firing side surface (35) to the coolant side surface (34). The cylinder bores (18) form a centerline defining an intake side (26) of the firing deck (16) and an exhaust side (28) of the firing deck. A plurality of bosses (30) through the deck (16) from the firing side surface (35) to the coolant side surface (34) are disposed around each cylinder bore (18). A plurality of anti-distortion projections (36, 136) are disposed on the coolant side surface (34) of the firing deck (16) and provide the firing deck with a varied thickness. The anti-distortion projections (36, 136) are disposed on both the intake side (26) and the exhaust side (28) of the firing deck (16).