Welded Profile Fluid Distribution Element for Piston Engines

Solution Overview

Problem

Existing fluid distribution elements for piston engines are cumbersome and inflexible, requiring multiple cast segments or costly extrusion dies, which lead to heavy, vibration-prone structures and limited adaptability to different engine dimensions and variants, necessitating frequent machining and maintenance.

Innovation Solution

A fluid distribution element composed of separate longitudinal profile pieces arranged side-by-side, which can be easily configured for various lengths and dimensions, and joined by welding, allowing for greater versatility and reduced material costs by minimizing the need for custom molds and extrusion dies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple cast segments are used to form the fluid distribution element, then the structure can withstand vibrations and ensure secure coupling, but the segments become heavy and require frequent machining and sealing maintenance

Engineering Contradiction:

Improvevibration resistanceVSAvoidsegment weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The fluid distribution element is divided into multiple separate profile pieces that can be individually manufactured and then joined together. This allows each segment to be optimized for weight reduction while maintaining the overall structural integrity needed for vibration resistance in piston engines.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If separate cast segments are used for different engine types, then adaptability to various engine dimensions is achieved, but multiple casting molds are required increasing manufacturing complexity and cost

Engineering Contradiction:

Improveengine type adaptabilityVSAvoidmold variety

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

A single universal profile piece design can be used across different engine types by varying only the length and number of segments, eliminating the need for multiple specialized casting molds. The standardized profile can be produced using one mold and then cut to different lengths as needed for different engine configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The fluid distribution element is divided into multiple separate profile pieces that can be individually manufactured and then joined together. This allows each segment to be optimized for weight reduction while maintaining the overall structural integrity needed for vibration resistance in piston engines.

Inventive Principle:

Principle #1Segmentation

3Productivity

If extrusion dies and mandrels are used for continuous production, then manufacturing efficiency is improved, but the dies are costly and time-consuming to replace for different engine types

Engineering Contradiction:

Improvecontinuous manufacturingVSAvoiddie-mandrel replacement

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The fluid distribution element is divided into multiple separate profile pieces that can be individually manufactured and then joined together. This allows each segment to be optimized for weight reduction while maintaining the overall structural integrity needed for vibration resistance in piston engines.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The profile pieces are designed to be produced using simple, inexpensive processes rather than requiring expensive, specialized extrusion dies. This eliminates the need for costly die-mandrel sets and reduces replacement time when different engine types are produced.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Reliability

If cast segments are used to form the fluid distribution element, then fluid-tight seals are achieved, but the mating surfaces require periodic checking and maintenance due to vibrations

Engineering Contradiction:

Improvefluid-tightnessVSAvoidseal maintenance

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The traditional mechanical sealing approach using cast segments with machined mating surfaces is replaced by a welding-based joining method. Welding provides permanent, vibration-resistant joints that maintain fluid-tightness without requiring periodic maintenance of sealing surfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 configuration enables efficient, lightweight, and adaptable fluid distribution systems that maintain fluid-tightness even in high vibration conditions, reducing manufacturing complexity and costs while accommodating diverse engine dimensions and variants.

Implementation Method 1

adjacent profile pieces are adjoined by welding

Methodology Applied

Scientific EffectWelding: Welding

Data Source

PatentEP3724485B1A piston engine equipped with a fluid distribution element

Publication Date: 2022.02.09 WARTSILA FINLAND OY

Figure 1~2

AI summary

A fluid distribution element (1) for a piston engine, having at least two longitudinal parallel fluid channels (2a, 2b, 2c, 2d) adjacent to each other. Each of the fluid channels comprises an inlet (3a, 3b, 3c, 3d), and, for at least one cylinder in an associated bank of the respective piston engine, an outlet (4a, 4a', 4b, 4c, 4d) for providing fluid communication between the fluid channel and a respective cylinder head. The fluid channels are defined by separate longitudinal profile pieces (5a, 5b, 5c, 5d) arranged side-by-side, such that adjacent profile pieces are adjoined by welding, so as to form at least two closed cross- sectional profiles defining the at least two fluid channels. A fixture arrangement (6) is provided for fixing the fluid distribution element to the respective piston engine.