Monolithic Rocker Arm Lattice Structure Oil Delivery
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Solution Overview
Problem
Existing rocker arms in internal combustion engines are heavy and have high moments of inertia, which reduces efficiency and durability, and they lack effective oil delivery mechanisms to enhance performance and longevity.
Innovation Solution
A lightweight, monolithic rocker arm component with a lattice structure and optimized geometry is manufactured using additive manufacturing, featuring a pushrod receiving member and a tongue element that directs oil flow for improved lubrication and reduced mass, allowing for a lower center of mass and moment of inertia, and incorporating a protective coating for wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional cast rocker arms are used, then manufacturing simplicity is maintained, but mass and moment of inertia are excessive reducing efficiency
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional casting methods to additive manufacturing, enabling complex lattice structures and optimized geometries that reduce mass while maintaining manufacturability. The additive manufacturing process allows for precise control of material deposition, creating lightweight structures with optimized mass distribution.
Solution Approach 2:
The patent incorporates porous materials through lattice structures within the rocker arm body. These lattice structures reduce overall mass and moment of inertia while maintaining structural integrity. The porous architecture allows for weight reduction of up to 15% compared to solid cast components.
2Weight of moving object
If rocker arm mass is reduced, then efficiency is enhanced, but durability may be compromised
Solution Approach 1:
The patent applies local quality by implementing a protective coating on specific surfaces of the rocker arm that experience high wear. This coating provides enhanced durability and wear resistance at critical locations while maintaining the overall lightweight structure. The tongue element and pushrod receiving member receive specialized coating treatment.
Solution Approach 2:
The patent uses composite materials by combining the base rocker arm material with a protective coating layer. This composite structure provides both the weight reduction benefits of the lightweight base material and the durability benefits of the protective coating, creating a multi-material system that optimizes both mass and reliability.
3Weight of moving object
If additive manufacturing with lattice structure is used, then mass reduction is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by performing computational optimization and simulation before the actual additive manufacturing process. Digital models are used to optimize the lattice structure geometry, mass distribution, and structural integrity before fabrication. This preliminary digital prototyping ensures that the final manufactured component meets precision requirements.
4Reliability
If oil delivery mechanism is added, then lubrication is improved, but device complexity increases
Solution Approach 1:
The patent merges the oil delivery mechanism with the rocker arm body itself, integrating lubrication channels and oil reservoirs directly into the additive manufactured structure. This integration eliminates the need for separate external oil delivery components, reducing overall system complexity while improving lubrication effectiveness. The oil delivery features are built as part of the monolithic rocker arm structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a rocker arm with reduced mass and improved efficiency, enhanced durability, and efficient oil delivery, leading to increased performance and extended lifespan, with a mass reduction of up to 15% compared to cast components.
Implementation Method 1
The rocker component is configured such that oil is introduced upward through the oil receiving aperture, deflected off of the second portion of the second surface of the pushrod receiving member, and directed toward the second end such that it flows along at least one surface of the tongue element.
Implementation Method 2
The first surface of the pushrod receiving member having the contour and the third surface of the tongue element include a protective coating disposed thereon.
Data Source
AI summary
A monolithic rocker arm component includes a first lateral wall defining a first aperture and a first mass reducing feature, an opposing second wall defining a second aperture and a second mass reducing feature, a pushrod receiving member that bridges the first lateral wall and the second lateral wall at a first end of the rocker arm, and a tongue element that bridges the first lateral wall and the second lateral wall at a second end of the rocker arm. The pushrod receiving member routes oil from the first towards the second end. The monolithic rocker arm may have one or more internal regions having lattice structures. Methods for additive manufacturing the monolithic rocker component are also provided.