Piston Cooling Gallery and Inner Collar Design
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Solution Overview
Problem
Existing piston designs face challenges in reducing frictional losses and providing effective cooling while simplifying construction, especially with complex and costly central cooling galleries.
Innovation Solution
A piston assembly design featuring a monobloc structure with a radially extending cooling gallery and an inner collar that encloses the central region, allowing for efficient coolant circulation and reduced friction, formed by securing the piston crown and skirt with friction welding or adhesive bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a peripheral cooling gallery is provided in the piston, then cooling efficiency is improved, but device complexity increases due to additional central galleries and communication passages
Solution Approach 1:
The invention extracts and eliminates the complex central cooling gallery and communication passages from the piston structure. By removing these unnecessary components, the design achieves effective cooling through the peripheral gallery alone, thereby reducing device complexity while maintaining cooling efficiency.
Solution Approach 2:
The cooling system is segmented to use only the peripheral cooling gallery rather than requiring both central and peripheral galleries. This segmentation simplifies the overall structure by focusing cooling functionality in one specific location, reducing the number of components needed.
2Use of energy by moving object
If the piston weight is reduced to increase efficiency, then energy consumption decreases, but structural strength and cooling capability are compromised
Solution Approach 1:
The piston design applies local quality by providing cooling functionality only where needed through the peripheral gallery, rather than requiring uniform structural reinforcement throughout. This allows weight reduction in non-critical areas while maintaining strength and cooling capability in critical regions.
3Temperature
If central cooling galleries are added to the piston, then cooling coverage is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The invention removes the complex central cooling gallery structure that increases manufacturing difficulty. By relying solely on the peripheral gallery, the design maintains adequate cooling coverage while significantly improving ease of manufacture through simpler machining requirements.
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 design enhances cooling efficiency, reduces frictional losses, and simplifies construction by integrating the crown and skirt into a single, robust unit, improving the piston's durability and operational stability under increased stress conditions.
Implementation Method 1
a cooling gallery may be provided about a perimeter of the piston, into which crankcase oil may be introduced to reduce the operating temperature of the piston
Implementation Method 2
formed by securing the piston crown and skirt through welding or adhesive bonding
Implementation Method 3
formed by securing the piston crown and skirt through welding or adhesive bonding
Data Source
AI summary
An exemplary piston assembly and method of making the same are disclosed. An exemplary piston assembly may include a piston crown and skirt. The crown may include radially inner and outer crown mating surfaces, and the crown may define at least in part a cooling gallery extending about a periphery of the crown. The skirt may further include an inner collar wall disposed radially inwardly of a radially inner interface region and extending upwards to a free end. The collar wall may generally enclose the radially inner interface region from the central region.