Piston Ring Zone Wall Gap Design for Cooling Channel Forming
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Solution Overview
Problem
Existing methods for producing cooling channel pistons in internal combustion engines often result in undesirable deformation of the ring zone wall during the forming process, leading to potential functional issues with the rings and increased component weight, which is a challenge in modern engines where weight reduction and improved performance are critical.
Innovation Solution
A method that involves forming a defined gap between the end of the ring zone wall and the upper edge of the piston skirt, allowing the ring zone wall to be freely deformed without compression, and incorporating a shoulder on the cooling channel lower wall to enhance contact area and reduce material, thereby preventing deformation and enabling intentional deformation to the contact area without hindrance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the collar is reshaped to form a closed cooling channel with complete contact to the contact area, then the cooling channel is sealed, but the ring zone wall is compressed and deformed uncontrollably
Solution Approach 1:
The contact area is segmented into two distinct zones: a first contact area that accepts the ring zone wall with a defined gap to prevent compression, and a second contact area that provides additional support. This segmentation allows the ring zone wall to be properly positioned without being compressed or deformed during the forming process.
Solution Approach 2:
The defined gap is预先 established in the piston blank between the first and second contact areas. This preliminary structural feature ensures that during the collar reshaping process, the ring zone wall is positioned correctly without experiencing compressive forces that would cause unwanted deformation.
2Ease of manufacture
If the ring zone wall is allowed to deform freely during forming, then manufacturing tolerances are accommodated, but the ring function is negatively affected
Solution Approach 1:
The contact area is divided into two zones with different functions: the first contact area with a defined gap that prevents compression, and the second contact area that provides additional support. This segmentation ensures the ring zone wall is positioned correctly without being compressed, maintaining ring function while accommodating manufacturing tolerances.
Solution Approach 2:
The defined gap acts as an intermediary element between the ring zone wall and the piston blank. It allows the ring zone wall to be positioned correctly while preventing direct compressive contact that would cause deformation and negatively affect ring function.
3Weight of moving object
If material is removed to reduce piston weight, then engine forces and friction are reduced, but the structural integrity may be compromised
Solution Approach 1:
Material is selectively removed from specific regions of the piston (such as the piston crown and cooling channel areas) while maintaining the structural integrity of critical load-bearing regions. The defined gap and two-zone contact area structure ensure that weight reduction does not compromise the strength where it is most needed.
Solution Approach 2:
The piston structure is segmented into regions where material can be safely removed (non-critical areas) and regions where material must be retained (critical load-bearing areas). The defined gap and contact area configuration allows optimal material distribution for strength-to-weight ratio.
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
This approach reduces the weight of the piston, improves ring function, and minimizes deformation, resulting in reduced engine forces, friction, and material savings, while also simplifying the manufacturing process by potentially eliminating the need for additional welding steps.
Implementation Method 1
the collar is reshaped in such a way that the inner surface of its outer radially circumferential edge comes very close or completely to the contact area to form a closed cooling channel
Data Source
Figure 1
AI summary
The invention relates to a method for producing a cooling channel system (1) for an internal combustion engine, which has a cooling channel (4) in the piston crown (2) thereof, the piston crown (2) being adjoined by a lower piston part having a piston boss, pin bores (6) and piston skirts (5), wherein, firstly, a piston blank having a peripheral collar projecting radially in the region of the piston crown (2) is produced, wherein the collar, forming a subsequent ring zone wall (7), is then reshaped and, in a transition area (12) between the piston crown (2) and the lower piston part, a contact area for the collar is formed, and the collar is reshaped in such a way until the outer radially peripheral edge thereof comes very close to or completely into contact with the contact area in order to form a closed cooling channel (4). The invention is characterized in that, following the reshaping, the end region of the ring zone wall (7) forms a defined gap (X) with respect to the upper edge of the piston skirt (5).