Piston Cooling Conduit via Gudgeon Pin Locking
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Solution Overview
Problem
Large internal combustion diesel engines face challenges in withstanding increased cylinder pressures and improving fatigue resistance while maintaining economical production costs, with existing pistons often failing to provide reliable operation and efficient cooling.
Innovation Solution
A piston assembly with a gudgeon pin configured to be lockable in a specific rotational orientation, forming a cross-sectionally closed conduit for cooling oil supply from the connecting rod to the cooling gallery, reducing surface pressure and enhancing fatigue resistance by positioning conduits in less stressed areas and increasing the bearing surface area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gudgeon pin is made lockable in a specific rotational orientation with a closed conduit, then the fatigue resistance and cooling efficiency are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The gudgeon pin is segmented into functional zones: a locked rotational orientation mechanism, a closed conduit system for cooling oil, and bearing surfaces. This segmentation allows each component to be optimized independently for its specific function while maintaining overall reliability and fatigue resistance.
Solution Approach 2:
The closed conduit for cooling oil is nested within the gudgeon pin structure itself, utilizing the internal space of the pin to house the cooling passage. This nesting approach integrates multiple functions (structural support, rotation locking, and cooling) into a single component, improving reliability without proportionally increasing complexity.
2Temperature
If the conduit is formed as a cross-sectionally closed conduit through the gudgeon pin, then the cooling efficiency and fatigue resistance are improved, but the manufacturing precision requirements increase
Solution Approach 1:
The closed conduit is pre-formed within the gudgeon pin structure during manufacturing, with the cooling oil passage established before final assembly. This preliminary formation of the cooling channel ensures proper positioning and geometry, achieving effective cooling while managing manufacturing precision requirements through planned sequential fabrication.
3Reliability
If the gudgeon pin is lockable to a given rotational orientation, then the bearing surface area is increased and surface pressure is reduced, but the ease of manufacture decreases
Solution Approach 1:
The gudgeon pin incorporates an asymmetric locking mechanism that defines a specific rotational orientation. This asymmetric design creates optimal bearing surfaces and cooling oil distribution patterns that enhance fatigue resistance, while the locking feature itself provides a manufacturable solution to achieve the desired geometric configuration.
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 effectively increases the piston's ability to withstand elevated cylinder pressures and improve fatigue resistance, while maintaining a balanced manufacturing cost and technical excellence, ensuring reliable operation and efficient cooling.
Implementation Method 1
a conduit (47) for supplying cooling oil from the connecting rod (5) via the gudgeon pin (4) to the bosses (32) and further to a cooling gallery (23) between the top part (2) and the body part (3)
Implementation Method 2
supplying cooling oil from the connecting rod (5) via the gudgeon pin (4) to the bosses (32) and further to a cooling gallery (23)
Data Source
AI summary
A piston assembly for internal combustion diesel engine having a piston diameter of 160-650 mm, the piston assembly including a top part, a body part and a gudgeon pin connectable to each other, the top part defining, when installed in a cylinder, the piston side of a combustion chamber, and the body part having an aperture for a gudgeon pin, bosses for distributing forces between the piston and the gudgeon pin, the body part having an interior, an outer surface and operable connecting surfaces, the gudgeon pin for pivotally connecting the piston to a connecting rod, is configured to be assembled and lockable by locking elements to the body part aperture in a given rotational orientation such that there is provided a conduit for supplying cooling oil from the connecting rod via the gudgeon pin to the bosses and to a cooling gallery between the top and body parts.