Skip Cycle Engine
Skip Cycle Engine
Skip Cycle Engine
(10)
And for the locking plate equation can be written as given
below:
1 vs vsi scm
vs vs
F F F m y
F k y
(11)
As both equations (10)-(11) are simultaneously solved the net
force yields:
( )
c k eff vs vsi net scm
F t F m y F F F m y (12)
The mass properties of the newly designed components
were estimated by means of CAD software. The mass of skip-
cycle mechanism contains plunger, spring retainer, locking
plate, half collets and also includes one-third of the actual
effective weight of plunger spring.
1/ 3 2
scm sr lp pl ps hc
m m m m m m (13)
Some modifications are required during constituting the
dynamically equivalent model of the valve disabled mode. The
mass of the plunger and the spring rate of the plunger spring,
represented relatively as m
pl
and k
ps
, are attached to the system
displacement of the original model (Fig. 8) and the
dynamically equivalent model for the valve disabled mode
(Fig. 11a) and the free-body diagram of the plunger (Fig. 11b)
are obtained.
m
eff
Cam
Cam Motion
k
eff
y
y
c
F
c
(t)
m
pl
F
k
F
2
F
2
F
2
F
ps
F
psi
m
pl
m
eff
k
ps
(a) (b)
Fig. 11 Valve disabled mode of the skip-cycle mechanism: a) Dynamically
equivalent model; b) Free-body diagram
The equilibrium of vertical forces can be written for the
plunger as given below:
( )
c k eff ps psi net pl
F t F m y F F F m y (14)
D. Determination of Cam Profile and Actual Cam
Displacement
The polydyne cam, which is defined by means of
polynomial equation, was chosen as it generally preferred in
highly flexible and high-speed mechanisms [11]. As long as
manufacturing accuracy is justified, the polynomial curve
shows excellent performance, because there is no sudden
change in acceleration at the intersection of the dwell periods
and the rise curve.
The 3-4-5 polynomial is consistent as the displacement
equation. As simultaneously solved, the boundary conditions
substituted in the general polynomial equation. So, the
equations yield for unit maximum rise in a unit cam angle:
3 4 6
2 3 4
2 3
1 10 15 6
30 60 30
60 180 120
y
y
y
(15)
The displacement formula has units in mm and the acceleration
formula has units in millimeter/degree
2
(15). It is convenient to
change the independent variable from the cam angle to the
time t by multiplying the equation with 36s
2
, where s is the
speed of the cam (rpm).
Furthermore, it is compulsory substituting the actual rise
and cam angle to give the particular equation of skip-cycle
mechanism. The conversion is accomplished by multiplying
each term of polynomial by the ratio K
n
, where is the total
World Academy of Science, Engineering and Technology 53 2009
408
cam angle from initial point to maximum rise, and h is the total
rise in cam angle . The displacement formula is derived for
the cam side (A) of the mechanism. Nevertheless, the
displacement at the valve side (B) is different due to the lever
ratio of the rocker arm (16).
n
A n
n
B
B n
A
y hC
l
y hC
l
(16)
The polydyne method is applied when designing the actual
cam profile, as it cannot be assumed that the follower lift and
the cam lift is the same due to clearances and the flexibility of
the system. Designing the cam profile to give the desired
follower action, polydyne method was derived by Rothbart
[11] as given below:
eff s
vsi
c
eff eff eff
c a r
k k
L F m
y y y
k k k
y r k y cy
(17)
where L is the external load and zero for this case, F
vsi
is the
preload of the valve spring, r
a
is the ramp height, which is the
sum of the initial static deflection r
s
and clearances of backlash
in linkage r
k
. Initial static deflection is negligible in calculation
because it is small when compared with static deflection.
Finally, k
r
is the spring ratio constant, which is related to the
spring constant of the system k
eff
and the valve spring k
vs
, and c
is the dynamic constant.
V. RESULTS OF THE FORCE AND STRENGTH ANALYSIS
The dynamic force analysis was performed for both mode of
the mechanism at a cam speed of 1500 rpm, which is the
maximum speed of the Anadolu Motor`s gasoline engine. The
tappet raises 6.55 mm in with 70 degrees of cam rotation. So,
the maximum acceleration at cam side was found
approximately 650 m/s
2
, however, at the valve side due to
lever ratio of the rocker arm it increases to 1000 m/s
2
. So, the
completely reversed cyclic fluctuating loads are illustrated in
(Fig. 12), which was calculated for the locking plate and the
plunger.
A. Locking Plate
The plate is subjected to a completely reversed axial force
of 150 N. As the actual shearing stress distribution is not
uniform, the maximum direct shearing stress at neutral axis for
cylindrical section shape is equal to:
4
3
a
F
A
(18)
where A is the cross-sectional area of the plate and F
a
is the
alternating load amplitude. Consequently, the shearing stress is
found 6.4 MPa (18). As the locking plate is made from the
same material of the spring retainer (AISI 1050, normalized at
900C), the desired fatigue life is obtained according to the
Smith diagram of the material [12].
Fig. 12 The fluctuating load acting on the plunger and the locking plate
B. Plunger Spring
As the spring generates a reaction force only proportional
with maximum deflection and the spring rate, the purpose of
the spring is not compensate the inertial force of the plunger.
However, it is subjected to a fluctuating load and so; the shear
stress in the coil is calculated according to the formula given;
3
8
a
a w
F D
K
d
(18)
where K
w
is Wahl`s factor, which considers both direct shear
stress and the stress concentration due to curvature, and F
a
is
the alternating load (18.25 N). The alternating shear stress in
the coil found 300.5 MPa and consequently, the spring-wire
has a torsional endurance limit which for peened springs is
approximately 465 MPa (Table II) [13].
TABLE II
THE ENDURANCE LIMIT OF SPRINGS
S
ew
310 MPa for unpeened springs
S
ew
465 MPa for peened springs
VI. CONCLUSION & FUTURE WORK
A novel skip cycle mechanism for the Anadolu Motor`s
gasoline engine was presented. The design was focused on the
leakage problem of the rotary valves, which especially affects
the efficiency of the skip-cycle strategy at high speeds and
loads. As the valves stay in closed position, an absolute sealing
is obtained. Furthermore, this proposed mechanism allows to
perform different skip cycle scenarios for different engine
speeds and loads. Although this solution is proposed for a
single cylinder engine, it could be adopted for the multi
cylinder engines.
Future work will focus on the actuation of the locking plate
because it is not considered as a problem of this study. The
geometry of the plate could change depending on the new
solutions of actuating mechanism. A linear solenoid, linear
motor or a new cam mechanism may bring a satisfactory
solution.
World Academy of Science, Engineering and Technology 53 2009
409
ACKNOWLEDGMENT
Ismail Gerzeli is greatful to Ceren Demirkesen and Dilara
Yamac for their indispensable and greatly appreciated
supports.
The authors also wish to thank Abdulhadi Ozcalici from
Anadolu Motor Co. for his cooperation during this work.
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