Rocker Arm Assembly With Angled Towers for Straight Arm Geometry
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Solution Overview
Problem
Shaft mounted rocker arms in internal combustion engines require complex geometries to align with pushrods and valves, leading to manufacturing inefficiencies and increased breakage due to applied forces.
Innovation Solution
A rocker arm system with a base member, first and second rocker arms, and a saddle, featuring angled towers and straight profiles to connect rocker arms without offsets or angled ends, using fasteners to secure them to the base member, allowing efficient actuation of intake and exhaust valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If shaft mounted rocker arms use complex geometries to align with pushrods and valves, then alignment and actuation function are improved, but manufacturing complexity and breakage risk increase
Solution Approach 1:
The rocker arm system is divided into separate modular components: individual rocker arms, a base member with mounting structures, and a saddle component. Each component can be manufactured independently with simpler geometries, then assembled together to achieve the required alignment and functionality.
Solution Approach 2:
The base member acts as an intermediary structure that provides mounting points and alignment references for the rocker arms. The saddle component serves as another intermediary element that facilitates proper positioning and connection, allowing the rocker arms to achieve correct alignment without requiring complex inherent geometries.
2Ease of operation
If shaft mounted rocker arms use complex geometries to align with pushrods and valves, then alignment function is improved, but manufacturing efficiency deteriorates
Solution Approach 1:
By segmenting the rocker arm system into separate manufacturable components with simpler geometries, each part can be produced more efficiently using standard manufacturing processes, reducing overall manufacturing complexity and improving productivity.
Solution Approach 2:
The base member and saddle components serve multiple functions: they provide structural support, enable alignment, facilitate assembly, and allow for potential interchangeability. This multi-functionality reduces the need for specialized complex geometries in individual rocker arms.
3Ease of operation
If shaft mounted rocker arms use complex geometries with offsets and angled ends, then alignment capability is improved, but durability and resistance to breakage worsen
Solution Approach 1:
The alignment function is separated from the rocker arm itself and transferred to the base member and saddle components. This allows the rocker arms to maintain simple, robust geometries that are more resistant to breakage while the supporting structures provide the necessary alignment capability.
Solution Approach 2:
The base member and saddle act as intermediary structures that bear and distribute the mechanical stresses and alignment requirements, protecting the simpler rocker arm components from excessive stress concentrations that would occur at offset sections and angled ends.
Data Source
AI summary
A rocker arm system for an internal combustion engine valvetrain includes a base member, a first rocker arm, a second rocker arm, and a saddle. The base member includes a first tower having a first tower recess, a second tower having a plurality of saddle mounting holes, a third tower having a third tower recess, a first rocker gap between the first tower and the second tower, and a second rocker gap between the second tower and the third tower. Each rocker arm includes an arm with a shaft extending through a shaft hole in the arm. A first tower recess central axis and a third tower recess central axis form a first angle having a measurement in a range of between 0° and 25°. The saddle is configured to connect to the second tower by passing a plurality of fasteners through plurality of corresponding saddle through holes in the saddle and into a plurality of corresponding saddle mounting holes in the second tower.