Piston Engines of the New Generation (Without turbo – supercharging)

Preface

The book presents a new edition of earlier published works of the author. The Russian name of this book is inherited from the article “How Make the Engine Better?” which was published in a very authoritative magazine “Russian Engineering Research”. The magazine is included in the list of approved by VAC RF for the publication of works of applicants of academic degrees [1]. The journal is translated into English, reprinted and distributed worldwide by Allerton Press (USA).

It is necessary that the information must be interesting for theorists and practitioners, specialists of the internal combustion engines, to publish an article in such an authoritative journal. Such grounds were. So the series of articles were published, not only in this journal but also in the profile journal “Automotive Industry”.

The book represents a new revision of another author’s book “Cylinder-piston Group of Engines and Compressors: 100% of the Innovative CPG Elements [3]. The contents of the book complement with new information, on inventions was received, the most significant practical proposals, designs, and justifications for their technological realization was reflected.

As a result of many years of searching for the reasons for the low efficiency of the engine, the specialist technologist found a fundamental error of the designers in the most important part of the design of the internal combustion engine (ICE) in cylinder-piston group (CPG).

This mistake claimed a scientific and technical sensation, because for the first time one of the main evidence of this event was published-the gas dynamics scheme of the piston compression ring. Which was opened a new direction in the design of the CPG elements for piston machines of various sizes and purposes.

The gasdynamic scheme and, based on its analysis, the formula of piston ring height determining, made it possible to supplement with the new data scientific and technical and educational literature devoted to solving problems of increasing the efficiency of the cylinder piston group and the engine itself.

In this publication, the attention of specialists is focused on the behaviour of gas dynamics at different cycles of the engine operating cycle. There is a really perspective to starting to improve the engine, in the designing and production process and in use during scheduled or unscheduled repairs.

More than 10 years passed, but the interest in the scientific community, has not appeared. The magazine articles and the textbooks published by the author remain unused. The mystery that the author had to decide and he had to believe he decided it. All this is described in more detail in the proposed edition.

In recent years, the human attitude towards scientific and technological progress has fundamentally changed. The problem of increasing the efficiency of lCE, the need “make the engine better” may be most revealing.

The author had to face with some problems of which did not help to solve the problem of improving the engine efficiency. Some approve principle changes in design others do not. We’ll try to understand these contradictions.

Start from the beginning of the product creation, with designers. Designers often develop a more complex design, forgetting that “simplicity is the sister of talent” and “the best is the enemy of the good”. In our work there is a concrete example, the “turbo-supercharging” of engines which is actively advertised and universally applied. The inexpediency of using the “supercharging”, the author tried to explain in his work [2].

The State Standards were one of the main causes of the artificial “brake” in the theoretical and practical researches. The author sent an article “Which GOST Standard is Better” in the Russian Standard and in the journal, the “Russian Engineering Research”. The editorial board after a long study, without any explanation, removed the article from the publication. The article has already been announced in the media, it was decided to place it in this book, believing that the reader would understand why the article had not published and including whether to use these Standards.

The manufacturer is the next stage in the creation of ICE. The task of the manufacturer to produce what the designers created. But that’s not quite true. They are not interested in the “simplicity” of the design. They are interested in more difficult technique with the higher cost and with great demand of its products. Maybe they want that the engine resource will be bigger. In fact, the less product’s resource, the greater the number it is planned for release.

There are a large number of people who do not want to increase the engine resource. It is a services and repair shops. Accordingly, these are millions of jobs. For the increase of which the state so insists.

Reduction of fuel and oil consumption does not inspire oil and fuel manufacturers. This all leads to a decrease in the receipts of taxes to the state budget.

In conclusion, it is possible to note that: only for the consumer and, perhaps, for the ecologists are important to have a powerful, highly resource, economical, and ecologically pure engine.

There is a violation of democratic principles, that is, a minority wins, but the whole of humanity is losing.

Nevertheless, science cannot stop, and to some extent it is confirmed by this work.

In the world practice of engine building, there are more than a billion units of only automobile engines in operation, a huge number of powerful and super-powerful marine diesel engines, stationary power plants of civil and military use are used.

The fundamental changes in the design of the cylinder piston group engines, presented by the author, will increase their effectiveness, resource and competitiveness. The book presents the results of studies of processes occurring in the engine cylinder, affecting the efficiency of the engine, the criterion of which is usually considered the efficiency of the engine.

It is clear that efficiency, which has now reached even 0.5, with the available scientific and technical achievements, cannot correspond to the energy product of the 21st century. There is a suspicion that not everything in the ICE (internal combustion engine) is good as theorists and practitioners consider. Obviously, there are principal reasons, probably of a subjective nature, that seriously affect the working processes in the cylinder-piston group. The author faced a task: to determine these causes and to try, if possible, to eliminate them. As studies have shown, there have been opportunities like this before and now.

There is no doubt about the urgency of the solving problem. Despite the emerging alternative ways and designs of engines, the dominant replacement of internal combustion engines in the coming decades is not expected, especially in such a huge country as Russia. To increase the efficiency of piston machines is not only a technical and economic task, but no less, and for large megacities, even more – an acute environmental challenge. In modern engines, less than half of the burnt fuel is used to perform useful work, and most of it negatively affects the biosphere.

Increased efficiency and resource, accompanied by the minimum allowable amount of harmful and polluting impurities in the exhaust gases, can translate ICE into the category of new generation engines. For specialists it is quite obvious that the cylinder-piston group basically solves this problem in the engine, in the interior of which physical, chemical and mechanical processes are performed. The effectiveness of these processes depends on the state of the kinematic system, its main elements “cylinder-piston rings-piston”.

It is known that the efficiency of an energy product depends on the various losses that accompany its work. The main losses in the engine operation are “gas leakage”, i.e. gas-dynamic losses, mechanical friction losses and thermal losses-thermodynamic losses. Approximately, even the magnitude of these losses, and the place of their origin is the GPG of the engine are known.

The cylinder piston group is the weakest link in the modern engine. With the failure of the CPG there is a necessity to perform engine overhauls. And the most vulnerable part of the CPG is the seal between the piston and the cylinder, which affects all processes occurring in the engine.

There are few specialists, scientists, practitioners who doubt that the modern internal combustion engine can be attributed to the latest achievement of science and technology of the 21st century. As researches have shown, the modern engine is considered perfect, there are no basis [3], [4]. The developers of ICE have not achieved the harmony between practice and theory. Uneconomically low efficiency of the engine, stopping at around 0.4, is evidence of a lack of serious theoretical developments in the design of the cylinder-piston group.

The problem of ICE effectiveness concerns the absolute majority of mankind. A huge number of different transport and special means using piston technology generated a large number of manufacturing firms and associations, small and medium businesses, which employ millions of jobs.

The quality of the equipment purchased and expensive is essential for determining demand and responsible supply.

Most often, the products are evaluated by the quality of its manufacture. For the energy product, the quality of the manufacture is also important, but the predominant characteristic must be its efficiency, based on the quality of design, construction and operation.

The main work in the kinematic scheme cylinder-piston ring-pistons produces a piston with very responsible structure elements-the piston rings. The cylinder, despite its significance, is a relatively static element of the engine design, the changes of which can be envisaged and reflected in its shape, size and technological processes. Therefore, the focus is on the simplest kinematic system of the ICE for the “piston-piston devices”.

Designing the new engine, or carrying out modernization of the engine in the course of scheduled or unscheduled repair, it is necessary to expect maximum efficiency which has to be significantly increased, that is the efficiency (E) of the engine has to be obviously more than 0,50. To increase the efficiency of the engine, it is necessary to exclude, or substantially reduce, all of the above losses.

The Internal combustion engine is not only the mechanics but also the physical processes that ensure its operation. The physical processes, in many ways, determine the mechanics of the engine, its shape and sizes, which then form the engine’s content, its technical and economic characteristics and its ecological performance.

The low efficiency of the engine is unacceptable-evidence of great losses and, as research has shown, most of them occur in the cylinder group.

This work is generally devoted to the research of gas-dynamic, hydraulic and thermodynamic processes impact occurring in the piston cylinder on main technical-economic and ecological showings of the engine.

Sealing Piston Devices

The internal combustion engine is subject to mechanical, gas-dynamic, hydrodynamic and thermodynamic influences that alter the shape and dimensions of its individual elements and parts that are in its natural and working conditions.

The developers who designing new engines, need to know what and how the physical processes affected to the transformation of the construction during the engine operation, which should be reflected in the developed projects.

The developers are not paying enough attention to these “physical processes”. We will consider in more detail what processes and in what part of the engine, cause changes. And what changes on which engine operation and its efficiency are depend.

The main source of changes in the engine is the cylinder-piston group, in which the main physical and chemical processes occur. They naturally affect to the operation of the engine. The cylinder-piston group determines not only the dimensions of the main engine elements, the connecting rod, the crankshaft and etc., but also the shape of the engine. Let’s try to figure this out.

The efficiency of any power device is estimated by the value of the efficiency, tending to unity, depending on the complex of various losses accompanying the operation of this device.

The specifics of internal combustion engines are that, in addition to the normal mechanical losses on the friction of the mobile elements of the kinematic system, there are gas dynamic losses, hydrodynamic losses (motor oil) and thermodynamic losses.

The thermodynamic changes in the engine during its operation have a significant effect on the efficiency of the cylinder-piston group. The thermodynamics changes the shape and dimensions of the cylinder, the piston, the piston rings, and it almost affects on all the processes that occur in the engine.

The engine losses may be objective, because of any physical process occurring within the construction, which is difficult for the developer and user to use during the operation of the product. But they can also be subjective because of the human factor that allows mistakes in the design, manufacture and operation of an energy device.

To significantly increase the efficiency of the engine, it was necessary to identify these errors and propose designs that exclude these losses, or reduce them to a negligible minimum. The example above shows that the opponent of the KAMAZ engine, the losses is much smaller and this naturally affects the efficiency of the engine, its shape and content.

The above losses, in general, should be attributed to the cylinder-piston engine group, which is rightly considered the “heart” of the motor that determines the technical and economic characteristics and ecological indicators of the engine. Low efficiency of the modern engine, this is, first of all, evidence of imperfection of the CPG engine and the errors committed during its design.