Piston Pin Hole Friction Torque Testing Under Engine Loads
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Solution Overview
Problem
Existing friction and wear testing devices for piston pins in engines struggle to simulate actual working conditions, particularly high temperature and load, and fail to provide real-time measurement of friction torque at the piston pin-seat and small head bushing holes, while also deviating from the actual lubrication conditions in high-strength marine engines.
Innovation Solution
A piston pin hole friction and wear test device that includes a driving system, loading system, oil supply system, temperature control system, and central controller, capable of simulating actual engine conditions to measure friction torque in real-time at the piston pin-seat and small head bushing holes, and replicating the engine's oil supply and thermal load.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If component-level tests are conducted using complete engine components to simulate piston pin oscillation, then the actual relative oscillation and working conditions can be simulated, but the friction torque cannot be measured in real-time and the lubrication conditions differ from actual working conditions
Solution Approach 1:
The test device is segmented into multiple independent measurement systems: a total friction torque measurement device and a small head hole friction torque measurement device. Each system can independently measure friction torque at specific locations, enabling simultaneous real-time measurement of friction torque at both the piston pin-seat hole and piston pin-small head hole while maintaining component-level simulation of actual working conditions
Solution Approach 2:
Torque sensors are introduced as intermediary measurement elements between the piston pin and the measurement devices. The torque sensors convert the friction torque into measurable signals, enabling real-time detection of friction torque at the piston pin-seat hole and piston pin-small head hole without interfering with the oscillation motion or lubrication conditions
2Ease of manufacture
If material-level friction and wear tests are conducted using standard testing machines, then the test setup is simple, but the actual relative oscillation and working conditions such as temperature and load cannot be simulated
Solution Approach 1:
The test device integrates multiple functions into a single system: it can simulate actual engine oscillation motion, apply high temperature and load conditions, provide real-time friction torque measurement, and replicate lubrication conditions. This multi-functional design enables component-level testing that accurately represents actual working conditions while maintaining a unified test setup
Solution Approach 2:
The device dynamically adjusts key parameters including temperature, load, and lubrication conditions to match actual engine working conditions. The oscillation frequency, amplitude, and load magnitude can be changed to simulate different operating states, enabling reliable friction and wear testing under conditions that reflect real engine operation
3Device complexity
If the lubrication system is simplified for testing, then the test setup is easier, but the lubrication conditions during tests differ from actual working conditions in high-strength marine engines
Solution Approach 1:
The lubrication system is designed with nested oil channels that replicate the actual engine lubrication pathway. The oil channels are nested within the piston pin, connecting rod, and piston components, allowing lubricating oil to flow through the same pathway as in actual engine operation. This nested structure enables accurate simulation of lubrication conditions without requiring a completely separate lubrication system
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
Enables simultaneous measurement of friction torque at multiple positions, accurately simulates actual engine conditions, and supports the study of piston pin-hole oscillation friction pairs in high-power and high-strength engines.
Implementation Method 1
the friction torque measurement system comprises a total friction torque measurement device and a small head hole friction torque measurement device
Implementation Method 2
The loading system comprises a fixing sleeve, a compensation arm, and a hydraulic cylinder
Implementation Method 3
an output shaft of the eccentric disc matches a driving groove at a bottom of the rocker arm
Implementation Method 4
The oil supply system comprises an oil pump, an oil tank, and an oil delivery pipeline
Implementation Method 5
the temperature control system comprises an electromagnetic heating wire device and a temperature sensor
Data Source
AI summary
A piston pin hole friction and wear test and torque measurement device in power machinery field, comprising a driving system, a torque measurement system, a loading system, a temperature control system, an oil supply system and a central controller. The driving system simulates the oscillation of the connecting rod. The loading system simulates the time-varying cylinder pressure load. The oil supply system and the oil channels of the connecting rod, bushing, and piston pin simulate the oil supply state. The torque measurement system comprises a total friction torque measurement device and a small head bushing hole friction torque measurement device, and measures the friction torque at the piston pin seat hole and the piston pin small head hole in real time. The temperature control system simulates the thermal load. The present application carries out tests based on actual components and realizes real-time measurement of friction torques.