Piston Ring Wear Indicator via Protruding Structure
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Solution Overview
Problem
Current methods for assessing piston ring wear in internal combustion engines are unreliable due to limited space and high measurement errors, making it difficult to determine wear without removing the piston ring from the piston ring groove or engine, and there is no existing solution to monitor wear without disassembly.
Innovation Solution
A piston ring with a wear indicator featuring a protruding structure on its outer surface, covered by an anti-wear layer, where the layer's thickness is reduced over the structure, allowing visual inspection of the structure's exposure to indicate remaining wear thickness without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection or layer thickness measurement is used to assess piston ring wear, then wear can be evaluated, but measurement errors are large and reliable assessment is difficult due to limited space
Solution Approach 1:
The patent applies a color-coded wear indicator system where different colors indicate different wear stages. The wear indicator layer contains pigments that change color or reveal different colors as the anti-wear layer wears away, providing immediate visual feedback on wear progression without requiring precise measurements or disassembly.
Solution Approach 2:
The wear indicator structure is pre-configured during manufacturing with a protruding base structure and a wear indicator layer of specific thickness. This preliminary setup ensures that as wear progresses, the indicator becomes visible at predetermined wear stages, eliminating the need for complex measurement procedures during inspection.
2Reliability
If anti-wear layers are designed to last for the entire planned life of the piston ring, then wear protection is maximized, but no wear indicators are provided to indicate possible wear
Solution Approach 1:
The anti-wear layer is segmented into two functional parts: a thick anti-wear layer for protection and a thinner wear indicator layer on top. The wear indicator layer is designed to wear away at a controlled rate, revealing the base structure or changing appearance to indicate wear progression, while the main anti-wear layer continues to provide protection throughout the piston ring's service life.
Solution Approach 2:
The wear indicator layer acts as an intermediary between the anti-wear layer and the external environment. It provides visual information about wear status while being consumed in the process, serving as a sacrificial indicator that communicates wear progression without compromising the primary function of the anti-wear layer.
3Measurement precision
If the piston ring is removed from the piston ring groove for wear assessment, then accurate measurement is possible, but engine disassembly is required which is time-consuming and complex
Solution Approach 1:
The piston ring's wear indicator system is self-indicating, meaning it provides wear information automatically through visual inspection without requiring removal from the engine. The protruding base structure or color changes on the outer surface serve as built-in wear indicators that can be assessed through the piston ring groove or during routine maintenance, making the system self-diagnostic.
4Difficulty of detecting and measuring
If the protruding structure height is increased to improve visibility of wear indicator, then wear detection becomes easier, but the anti-wear layer thickness must be increased accordingly
Solution Approach 1:
The protruding base structure is located locally at specific positions on the piston ring's outer surface where visibility is most effective. Rather than increasing the overall anti-wear layer thickness uniformly, the design concentrates the indicator structure at strategic locations, allowing adequate visibility while maintaining optimal material distribution and minimizing total material usage.
Data Source
Figure 1~2B
Figure 3A~3B
Figure 4A~4B
AI summary
The invention relates to a piston ring (2) having wear indication (42), comprising a piston ring body (4). The piston ring body has an outer surface (6), an upper ring flank (8), and a lower ring flank (10). The outer surface (6) of the piston ring body (4) is provided with a structure (14) that protrudes outward by a height (h). A wear protection layer (12) is applied to the outer surface (6), which wear protection layer covers the protruding structure (14). The wear protection layer (12) has a thickness (D) that is reduced by the height (h) of the protruding structure in the region of the protruding structuring (14).