Segmented Cylinder Head Cooling Cavity Design
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Solution Overview
Problem
Current water-cooled internal combustion engine cylinder heads have complex configurations that make it difficult to manufacture using die-casting, as the complicated shapes of cooling water cavities, intake, and exhaust ducts hinder demoulding and core removal, limiting mass production efficiency and environmental sustainability.
Innovation Solution
The cylinder head is divided into separate parts, such as upper and lower parts, which are manufactured separately and integrated using methods like welding, adhering, bolting, or riveting, allowing for the formation of complex shapes like curved helical intake and exhaust ducts, facilitating die-casting and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling water cavity surrounds the outside walls of fuel injector receiving holes, intake ducts, and exhaust ducts with complicated configuration, then the cooling function is improved, but the manufacturing complexity increases and die-casting becomes impossible
Solution Approach 1:
The cylinder head is divided into multiple segments: an upper cylinder head part and a lower cylinder head part. The cooling water cavity is formed by integrating these separate parts, allowing complex cooling channels to be created without requiring complicated sand-mould cores. Each part can be manufactured independently using die-casting, then assembled together to form the complete cooling cavity structure.
Solution Approach 2:
The fuel injector receiving holes, intake ducts, and exhaust ducts are formed as nested structures within the cylinder head parts. The cooling water cavity surrounds these nested components, creating a multi-level integrated structure that achieves complex cooling functions while simplifying the manufacturing process through die-casting.
2Temperature
If the cooling water cavity has a complicated configuration to surround all components, then the cooling efficiency is improved, but the demoulding and core removal become difficult
Solution Approach 1:
By segmenting the cylinder head into upper and lower parts, the complicated cooling water cavity is created through assembly rather than through a single complex mould. This eliminates the need for difficult-to-remove sand-mould cores while maintaining the surrounding cooling structure that touches fuel injector receiving holes, intake ducts, and exhaust ducts.
Solution Approach 2:
Instead of forming the complicated cooling cavity in one piece using traditional sand-mould casting with internal cores, the invention inverts the approach by creating separate simpler parts and assembling them to form the complete cooling structure. This reversal of the manufacturing sequence simplifies demoulding while achieving the same cooling efficiency.
3Ease of manufacture
If sand-moulds and cores are used to form the complicated cooling water cavity, then the cylinder head can be manufactured, but environmental pollution increases
Solution Approach 1:
The invention replaces the traditional sand-mould casting mechanical system with a die-casting system. By using die-casting moulds to form separate cylinder head parts and assembling them, the process eliminates sand-mould breaking and core removal operations that generate environmental pollution, while still achieving complicated cooling water cavity configurations.
Solution Approach 2:
The manufacturing process parameters are changed from sand-mould casting to die-casting. This parameter change eliminates the use of binders and sands, removes the need for core breaking and removal, and consequently eliminates the environmental pollution associated with these operations while maintaining the ability to manufacture complicated cooling structures.
4Strength
If the cylinder head is manufactured as a single piece with complicated shapes, then the structural integrity is maintained, but mass production efficiency decreases
Solution Approach 1:
The cylinder head is segmented into upper and lower parts that can be manufactured separately using die-casting processes. This segmentation enables mass production of individual parts with high efficiency, and the parts are then assembled with fastening elements to maintain the structural integrity of the complete cylinder head assembly.
Solution Approach 2:
The upper and lower cylinder head parts are merged through assembly using fastening elements. This combining process maintains the structural integrity of the complete cylinder head while allowing each part to be manufactured separately with high productivity through die-casting, thus achieving both strength and mass production efficiency.
Data Source
AI summary
A cylinder head is prepared by integrating an upper cylinder head part and a lower cylinder head part, which are manufactured separately, into the whole, wherein the fuel injector receiving hole, the intake valve stem receiving hole and the exhaust valve stem receiving hole are respectively prepared by integrating their upper portions which are formed together with the upper cylinder head part and their lower portions which are formed together with the lower cylinder head part respectively; the intake duct and the exhaust duct are formed in the lower cylinder head part; the cylinder head water cavity is prepared by integrating an upper water cavity portion formed together with the upper cylinder head part and a lower water cavity portion formed together with the lower cylinder head part into the whole, alternatively, the cylinder head water cavity is formed, as a whole, with the lower cylinder head part.