Taper-Faced Compression Ring Wire for Rapid Lapping
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Solution Overview
Problem
Existing taper-faced compression rings face challenges in maintaining a consistent contact width during production, leading to increased lapping time and friction, which results in higher oil consumption and reduced fuel efficiency due to varying circularity and surface pressure.
Innovation Solution
Incorporating a second tapered portion with a larger inclination angle than the first tapered portion, and a specific projection length, allows for a predetermined contact width to be formed rapidly during lapping, reducing wear and maintaining surface pressure, thereby improving fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lapping is performed for a long period of time to improve running-in, then a contact surface is formed, but the production cost increases and productivity decreases
Solution Approach 1:
The invention applies preliminary action by pre-forming a tapered surface on the ring wire before the lapping process. This preliminary tapered surface serves as a foundation that guides the lapping process, enabling the contact surface to be formed more quickly and consistently without requiring prolonged lapping time, thus improving both reliability and productivity
2Reliability
If the contact width is increased to improve gas tightness, then sealing performance improves, but surface pressure decreases and oil consumption increases
Solution Approach 1:
The invention applies parameter changes by precisely controlling the contact width within the range of 0.05-0.30 mm and the tapering angle θ within 1-7 degrees. By optimizing these parameters, the contact surface achieves sufficient gas tightness while maintaining adequate surface pressure to minimize oil consumption, resolving the trade-off between sealing performance and oil loss
3Reliability
If the contact width is increased to ensure gas tightness, then sealing improves, but friction increases and fuel efficiency decreases
Solution Approach 1:
The invention optimizes the contact width parameter to 0.05-0.30 mm and the tapering angle to 1-7 degrees, achieving a balance where gas tightness is sufficient while friction losses are minimized. This parameter optimization ensures that the ring maintains adequate sealing without excessive contact area that would increase friction and reduce fuel efficiency
4Productivity
If a flat surface is formed in advance on the wire, then lapping time is reduced, but a predetermined contact width is not necessarily obtained depending on ring circularity
Solution Approach 1:
The invention pre-forms a tapered surface with specific geometric parameters (tapering angle and projected width) on the ring wire before lapping. This preliminary tapered geometry acts as a self-guiding feature that ensures consistent contact width formation during lapping, making the process less sensitive to variations in ring circularity while still reducing overall lapping time
Solution Approach 2:
By specifying precise parameters for the preliminary tapered surface (tapering angle θ of 1-7 degrees and projected width of 0.05-0.30 mm), the invention creates a controlled geometric foundation that guides the lapping process to produce consistent contact widths regardless of minor variations in ring circularity, thus achieving both productivity improvement and precision maintenance
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
The solution ensures a consistent contact width is achieved quickly, reducing oil consumption and friction, leading to improved fuel efficiency and prolonged surface pressure, even with engine wear.
Implementation Method 1
it is usually lapped in a sleeve having an inner diameter equal to a nominal diameter of the ring in a final production step, thereby forming a belt-like contact surface 4 on an outer peripheral surface 1 of the ring
Implementation Method 2
forms an oil film by an wedge effect between a tapered surface and an inner cylinder wall when a piston moves upward
Data Source
AI summary
To provide a wire for a taper-faced compression ring, which can be provided with a running-in surface (contact surface) uniformly and rapidly in the production process of the taper-faced compression ring, a surface of the wire corresponding to an outer peripheral surface of the ring is provided with adjacent outward inclined first and second tapered portions, the inclination angle θ2 of the second tapered portion being larger than the inclination angle θ1 of the first tapered portion, and an outer end of the second tapered portion being located radially outward than an outer end of the first tapered portion by 0.005-0.05 mm. A long-life taper-faced compression ring with reduced friction and improved fuel efficiency is formed by the above wire, the second tapered portion having a lapped surface located radially outward than an outer end of the first tapered portion by 0.001-0.048 mm.