Lubricating system, an engine and method for providing lubricant to an engine

The invention relates to a lubricating system for an internal combustion engine (1). The system includes a first conduit means (7) connecting a lubricant supply source (5) to the internal combustion engine (1) for supplying lubricant to the internal combustion engine (1). According to the invention, the system further includes a second conduit means (8) connecting a gas supply source to the first conduit means (7) for supplying gas to the first conduit means such that gas bubbles are formed in the first conduit means (7). A sensor (3) detects whether lubricant or whether gas is present in a certain part of the first conduit (7). The certain part being located downstream the connection of the second conduit means (8) to the first conduit means (7). A control unit (6) is connected to the sensor (3), which control unit (6) is arranged to determine whether lubricant is flowing through the first conduit means (7) or not, in response to the detections of the sensor (3). The invention also relates to an internal combustion engine, to a power tool and to a method for providing lubricant to an internal combustion engine.

TECHNICAL FIELD

The present invention relates to an engine and more specifically to lubrication of engines. The teachings herein even more specifically relates to an engine comprising a lubrication system for lubricating the engine and a method for providing lubrication to the engine.

BACKGROUND

Internal combustion engines rely on a steady or regular supply of lubricant to ensure that moving parts of the engine does not overheat or get subjected to excessive wear. Power tools are often equipped with engines that are provided with lubricant along with the fuel. This is often achieved by mixing the lubricant into the fuel in advance. The supply of lubricant can however also be performed automatically by a pump providing lubricant to the engine from a separate lubricant supply. Since mixing lubricant and fuel manually to the right proportions can be difficult and purchasing premixed fuel/lubricant mixture is more expensive than buying the lubricant and fuel separately, an engine with an automatic lubrication system is often preferred.

However, when the lubrication is performed automatically by the engine, it is important that the lubrication system is reliable since the user is unable of controlling that the right amount of lubricant is provided to the engine.

It is known in the art (related background art can be found for instance in US20130291831A1) to provide a sensor for detecting if lubricant is present in a lubrication conduit; however merely detecting if lubricant is present has proven unreliable since standing oil may be interpreted as a flow of lubricant. Since flow sensors are considered too complex and are expensive, a reliable and cost effective way of ensuring that lubricant is flowing in a conduit is preferred.

SUMMARY

It is an object of the present invention to provide a lubrication system for an internal combustion engine and a method for providing lubricant to the engine that is improved over prior art. It is also an object of the invention to provide an engine including the invented lubrication system and a power tool using said engine which is improved over prior art. This object is achieved by a concept having the features set forth in the appended independent claims; preferred embodiments thereof being defined in the related dependent claims.

According to a first aspect of the invention the object is met in that a lubrication system of the kind specified in the preamble of claim1includes the specific features specified in the characterizing portion thereof. The lubrication system thus includes a first conduit means connecting a lubricant supply source to the internal combustion engine for supplying lubricant to the internal combustion engine. The system thus further includes the specific features that it includes a second conduit means connecting a gas supply source to the first conduit means for supplying gas to the first conduit means such that gas bubbles are formed in the first conduit means, a sensor detecting whether lubricant or whether gas is present in a certain part of the first conduit, which certain part is located downstream the connection of the second conduit means to the first conduit means, and a control unit connected to the sensor, which control unit is arranged to determine whether lubricant is flowing through the first conduit means or not, in response to the detections of the sensor.

According to a preferred embodiment of the invented lubrication system a pump is located in the first conduit means for pumping the lubricant.

According to a further preferred embodiment, the second conduit means is connected to a gas supply source that has a pressure which, at operation of the system, is at least intermittently higher than the pressure where the second conduit means is connected to the first conduit means.

According to a further preferred embodiment, the sensor is arranged to transmit a binary signal to the control unit, which signal varies depending on whether gas or whether lubricant is present in said certain part.

According to a further preferred embodiment, the signal is an alternating signal if lubricant is present and a constant signal if gas is present, or vice versa.

According to a further preferred embodiment, the second conduit means comprises a check valve arranged to allow flow through the second conduit means only in the direction towards its connection to the first conduit means (7).

According to a further preferred embodiment, the first conduit means comprises a check valve downstream of the pump that allows flow only in the direction from the pump toward the check valve.

According to a further preferred embodiment, the sensor is an optical or a capacitive sensor.

According to a further preferred embodiment, the control unit is arranged to determine whether lubricant is flowing through the first conduit means at a flow rate within a predetermined range or not, in response to the detections of the sensor.

According to a further preferred embodiment, a user interface is connected to the control unit for alerting a user that flow of lubricant has stopped.

According to a further preferred embodiment, the user interface is arranged to alerting the user that flow of lubricant is outside a predetermined range for the flow rate.

According to a further preferred embodiment, at least one of the first conduit means and the second conduit means includes a restriction arranged to facilitate and control the formation of bubbles in the first conduit means.

According to a second aspect of the invention, the object is met in that an internal combustion engine includes the invented lubricating system, in particular according to any of the preferred embodiments thereof.

According to a preferred embodiment of the invented internal combustion engine, the control unit is arranged to perform an action, if it determines that the flow of lubricant has stopped, the action being one or several of:indicating that the flow of lubricant to the engine has stopped,restricting engine power output,stopping the engine.

According to a further preferred embodiment, the control unit is arranged to perform an action, if it determines that the flow of lubricant is outside a predetermined flow rate, the action being one or several of:indicating that the flow of lubricant to the engine is outside said range,restricting the engine power output,stopping the engine.

According to a further preferred embodiment, the second conduit means is connected to an intake of the engine as the gas supply source.

According to a further preferred embodiment, the first conduit means is connected to an intake of the engine for the supply of lubricant.

According to a further preferred embodiment, the intake of the engine comprises a venturi, and the first conduit means is connected to the venturi or to a position adjacent the venturi.

According to a further preferred embodiment, the first conduit means is connected to a narrow part of the venturi.

According to a further preferred embodiment, an intake of the engine comprises a throttle valve.

According to a further preferred embodiment, the throttle valve is positioned downstream of the venturi in relation to the flow direction in the intake.

According to a further preferred embodiment, the second conduit means is connected to the intake upstream of the throttle valve.

According to a further preferred embodiment, the second conduit is connected to the intake downstream of the throttle valve

According to a third aspect of the invention it relates to a power tool comprising the invented internal combustion engine, in particular according to any of the preferred embodiments thereof.

According to a preferred embodiment of the invented power tool, the tool is a cut-off saw, a chain saw, a hedge cutter, a lawn mover or a trimmer. According to a fourth aspect of the invention it relates to a method for providing lubricant to an internal combustion engine and includes the specific steps specified in the characterizing part thereof: The method thus includes providing lubricant from a lubricant supply source via a first conduit means (7) to the engine. The specific steps of the invention are:providing gas to the first conduit means via a second conduit means such that intermittent gas bubbles form in the first conduit means,using a sensor detecting whether lubricant or whether gas is present in a certain part of the first conduit means, which certain part is located downstream of the supply of gas from the second conduit means to the first conduit means,determining by a control unit connected to the sensor if lubricant is flowing through the first conduit means or not, in response to the detections of the sensor.

According to preferred embodiments of the invented method, the method is adapted to provide lubricant to an internal combustion engine according to the present invention, in particular according to any of the preferred embodiments thereof. These preferred embodiments of the method thus include the corresponding steps that are implied by the preferred embodiments of the internal combustion engine.

According to a further preferred embodiment, the method includes the step of evacuating lubricant from the first conduit means with the aid of the gas from the second conduit means if flow of lubricant stops such that the sensor only detects gas in the first conduit.

DETAILED DESCRIPTION OF EMBODIMENTS

With reference toFIG. 1, a simplified illustration of an engine1comprising a lubrication system according to the teachings herein is shown. For simplicity, a single cylinder engine1is shown however the lubrication system can equally well be applied to an engine configuration comprising a plurality of cylinders. The engine comprises a cylinder block1a,which comprises the cylinder(s) and the reciprocating piston(s) of the engine1. The engine further comprises a crankcase1b,onto which the cylinder block1ais attached.

The engine comprises at least one intake2, for supplying air and fuel mixture to engine1. The intake may also be used for supplying lubricant to the engine1along with the fuel/air mixture, which is often the case with 2-stroke and even some 4-stroke engines. This is especially common in engines being adapted for use in power tools.

The engine further comprises at least one exhaust14, which transport exhaust gases from the cylinder(s) of the engine1.

The engine1comprises a lubrication system, which provides lubrication to the engine1through a first conduit7. The lubricant provides lubrication to the moving parts in the engine1, for preventing overheating, excessive wear and eventual seizing of the engine1. The first conduit7is connected to a lubricant supply5, such as a reservoir or a sump. A pump4is provided which pumps lubricant from the supply5to an outlet7aof the first conduit7. Furthermore, a sensor3is provided for detecting presence or absence of lubricant (i.e. detecting presence of gas) in the first conduit7downstream of the pump4.

A second conduit8is provided which connects to the first conduit7downstream of the pump4, between the pump4and the sensor3. The second conduit8provides gas to the first conduit7, such that intermittent gas bubbles form in the first conduit7. Gas may include any of air, air-fuel mixture or air-fuel-lubricant mixture, which is capable of forming bubbles in the lubricant flow in the first conduit7. The bubbles will be transported along with the lubricant in the first conduit7to the outlet7aof the first conduit7, thereby flowing past the sensor3.

The embodiments herein are for simplicity described with one first conduit7and one second conduit8; however, a plurality of first conduits7and/or a plurality of second conduit8may equally well be used. For instance the first conduit7may be separated into two or more conduits downstream of the connection of the second conduit8to the first conduit7, thus enabling provision of lubricant to e.g. both the intake and the crank case of the engine1. A plurality of second conduits8, i.e. conduits for provision of gas to the first conduit may also be used for redundancy etc.

As is illustrated, the first7and second conduit8of the lubrication system may be connected to the intake2of the engine1; however the conduits7,8may be connected elsewhere as well. For instance, the first and/or the second conduit(s) may be connected to the crankcase1bof the engine1. The first and second conduits may be separate conduits7,8not being an integral part of the engine1, such as hoses or tubes. However, the conduits7,8may equally well be cast or formed as internal conduits7,8of the engine1or in a component of the engine1such as a carburetor. The second conduit8may also provide gas (i.e. air in this case) to the first conduit7from the surrounding of the engine1, in which case an air filter may be provided to prevent debris from entering the second conduit8.

The sensor3detects a pattern of alternating lubricant and gas (absence of lubricant) that flows past it, which may include duration of each passage lubricant or gas. An alternating pattern indicates that lubricant is flowing and the duration between two gas bubbles can be used to determine for instance that lubricant is being provided in a sufficient amount or not.

The gas is provided from the second conduit8into the first conduit7by a pressure difference between a first pressure P1acting where one end of the second conduit8connects and a second pressure acting P2in the first conduit7where the other end of the second conduit connects, P1being at least intermittently higher than P2. The intermittent i.e. alternating pressure difference is preferably generated by the operation of the engine1, providing an intermittent stream of gas to the first conduit7while the engine1is operating and lubricant is being provided by the pump4to the engine1.

The sensor3is provided to detect lubricant in the first conduit7, between the pump4and the outlet7aof the first conduit7, downstream of the connection of the second conduit8to the first conduit7. The sensor3may be a binary sensor, providing a binary signal indicating lubricant or no lubricant (i.e. presence of gas) in the first conduit7. An example of such a binary sensor3may be an optical sensor or a capacitive sensor or other similar sensors that are well suited for providing a binary signal and for detecting fluid such as lubricant in a conduit.

The sensor3is connected (directly or indirectly) to an engine control unit6, which is configured to interpret the signals from the sensor3and to determine if provision of lubricant is functioning or if provision of lubricant is disrupted. The intermittent gas bubbles that are formed in the flow of lubricant through the first conduit7will function as an indication that lubricant is being provided to the engine1. As long as the signal from the sensor3to the control unit6varies between lubricant and no lubricant (gas), flow of lubricant can be determined by the control unit6to be present. When the signal from the sensor3to the control unit6remains constant for a prolonged period of time, this will indicate that flow of lubricant is disrupted. Due to the capillary pressure in the first conduit7, the bubbles will be transported by the pumping of lubricant and thus is the orientation of conduits7,8not of high importance. If the pump4stops working while the engine1continues to operate, the pressure difference between P1and P2will ensure that the gas provided from the second conduit8into the first conduit7will evacuate the lubricant downstream of the second conduit8connection to the first conduit7.

InFIG. 2, an engine1is shown comprising a lubrication system according to one embodiment of the teachings herein. The engine1further comprises a venturi9or a narrowing portion9in the intake2. The first conduit7may be connected in or adjacent to the venturi9or even in the narrowest part of the venturi9where the low pressure and high velocity of the flow will distribute the lubricant efficiently into the gas which flows through the intake2. As is shown, the second conduit8may connect to the intake2downstream of the venturi9. However, the second conduit8may also be connected upstream of the venturi in the intake2or even directly to the surrounding environment.

The first and/or second conduits7,8may also be connected to other parts of the engine1. For instance, connecting the first and/or the second conduits7,8to the crankcase is also possible.

As is shown inFIG. 3, a throttle valve10may be provided in the intake2. The throttle valve regulates the flow in the intake2. The throttle valve10is shown in combination with an upstream venturi9, however the throttle valve10may equally well be provided in an intake2without a venturi9or with a venturi9downstream of the throttle valve10. The first and/or second conduit8may connect upstream or downstream of the throttle valve10.

As is shown inFIG. 4, one or both of the conduits7,8may comprise a check valve11,12. The check valve12in the first conduit7prevents the flow from reversing and overpowering the pump4. The risk of reverse flow increases when no venturi is present in the intake2, resulting in a higher pressure for the pump4to overcome when pumping lubricant into the intake2.

The check valve11in the second conduit8will ensure that flow of gas only occurs in one direction. Furthermore, it is ensured that no lubricant provided by the pump4flows into the second conduit8. The provision of check valves11,12allow larger freedom in placing the conduit7,8connections and makes the lubrication system more robust. The conduits7,8may for example be connected directly to the crankcase as long as the requisite regarding the pressure P1being intermittently higher than P2is fulfilled.

When a disruption in the lubrication to the engine1occurs, it is important that the user is made aware of this as soon as possible. In this purpose and to prevent damaging of the engine1, a restriction of the power outlet of the engine1may be implemented as an action by the control unit6. This may be achieved by altering ignition and/or restricting flow of fuel to the engine1. The ignition may be altered by for instance by omitting sparks and thereby restricting the engine from running at high speeds (RPM). This alone will in most applications suffice as a way of alerting a user of a problem with the lubrication. However, a user interface13, possibly comprising light emitting diodes, lamps, screens and/or audible signaling, may also be provided which will further clarify to the user that a lubrication problem has occurred. The user interface13being connected (directly or indirectly) to the control unit6, which may activate the user interface13when the control unit6determines that provision of lubricant has been disrupted.

With reference toFIG. 5, a method for providing lubricant to an engine1is presented. The method comprises providing S1lubricant by the pump4from the lubricant supply5via the first conduit7to the engine1, providing gas S2to the first conduit7via a second conduit8such that intermittent gas bubbles form in the first conduit7, detecting S3if lubricant or gas is present in the first conduit by the sensor3and determining S4by the control unit6connected to the sensor3if lubricant is flowing through the first conduit. S1to S4are performed continuously as the engine1is operating and the sequence will initiate when the engine1starts. The engine1being an internal combustion engine1, more specifically an internal combustion engine1which is provided with lubrication from a separate lubrication system.

The provision S1of lubricant to the engine1is performed by the lubrication pump4.

The provision S2of gas to the to the first conduit7via the second conduit8in order to generate intermittent gas bubbles in the first conduit7is achieved by a pressure difference between a first pressure P1acting where one end of the second conduit connects and a second pressure P2acting in the first conduit7where the other end of the second conduit8connects, P1being at least intermittently higher than P2. The pressure fluctuations between P1and P2may occur due to the operation of the engine1. As long as the prerequisite that the pressure P1is intermittently higher than P2is fulfilled, the positions of the connections of the first and second conduit can vary. Since P1is intermittently higher than P2, gas will be transported into the first conduit7and form intermittent bubbles which are detectable S3by the sensor.

As a result of the providing of intermittent gas into the first conduit7, the sensor3will detect an alternating pattern of lubricant and gas over time for as long as the engine1and the lubrication system are operating as intended. Thus can the control unit6determine S4that as long as the sensor3detects and transmits an alternating binary pattern, lubrication is being provided to the engine1. Should a prolonged period of only lubricant or only gas be detected, i.e. the sensor3generating a prolonged constant signal, this would indicate to the control unit6that the lubrication system is disrupted. If the periods of lubricant passing past the sensor3are too brief, this could also be indicating that the engine1is not receiving enough lubricant. Thus is both the longevity of each passing of lubricant or gas past the sensor3important as well as the number of lubricant/gas alternations per time unit.

The amount of gas bubbles (i.e. number of alterations between gas and lubricant) which forms in the first conduit7depends on several factors. Examples of such factors are fluctuations in the pressure difference between P1and P2, the relative dimensions of the first and second conduits7,8and the amount of lubricant which is being pumped by the pump4to name a few. The first7and/or the second conduit8may comprise restrictors to facilitate and control the formation of bubbles in the first conduit7.

As an engine1has varying demands on lubrication depending on the operating conditions, the lubrication system may be configured to only detect alternations between lubricant and gas during operation above certain RPM speeds or at certain throttle positions etc. For instance, during engine idle speeds, the engine1will manage extended periods without being provided with lubricant. And since the pressure fluctuations between P1and P2during idle engine speeds may be insufficient for producing gas bubbles in the first conduit7, detection of lubricant or gas by the sensor3may therefore be paused or aborted during engine1idle speed. Examples of such operating conditions may thus be the RPM of the engine1dropping below a predetermined RPM and/or closed throttle position etc. The lubrication pump4may also be configured to reduce provision of lubricant to the engine1during such operating conditions, either completely or to a certain extent.

Furthermore, the gas which is provided through the second conduit8into the first conduit7may evacuate the lubricant in the first conduit7in case of a pump4failure or other disruption to the lubrication system. This leads to the control unit6being able to separate a blockage in the second conduit8(prolonged period of only lubricant detected by the sensor3) from a disruption in the providing of lubricant (prolonged period of only gas/no lubricant detected by the sensor3).

When the control unit6determines that a disruption in the lubrication system is present, the performing an action S5may be initiated by the control unit6. The action may be one or both of (i) indicating to the user that the flow of lubricant to the engine has stopped and (ii) restricting engine power output. The action may also comprise (iii) shutting down the engine1, for instance if the user does not shut it down manually in a certain time period after the power output has been reduced and the indication has been activated. The indication to the user may be performed by the user interface13, which will further clarify to the user that a lubrication problem has caused the power of the engine1to be restricted.

The power outlet of the engine1is preferably restricted to such an extent that the power tool to which the engine1is mounted is rendered unusable, for instance by not allowing the engine1to exceed an RPM (revolution speed) required for engaging an engagement clutch, such as a centrifugal clutch, for engaging the tool.

Turning toFIGS. 6 to 9, various time-line diagrams of the signal from the sensor3is shown. InFIG. 6, the binary signal is shown alternating relatively regularly between 1 (indicating lubricant) and 0 (indicating gas). T0denotes the duration of each passing of gas and t1denotes the duration of each passing of lubricant. The duration of t0and t1may be performed by measuring time (e.g. seconds or milliseconds) and/or by counting the number of engine1revolutions per passing of gas/lubricant or between two lubricant passes. As the engine1RPM may also be a factor for the amount of lubricant that needs to be provided to the engine1, it may be beneficial to weigh this in when the control unit6determines whether sufficient lubricant is flowing. The diagram inFIG. 6indicates a functioning lubrication system.

InFIG. 7the provision of gas has been disrupted, leading to only lubricant being detected by the sensor3. Since this situation creates an uncertainty in the detection of flow of lubricant to the engine1, the control unit6may be arranged to indicate this by performing an action such as alerting the user by the user interface13or by restricting power outlet of the engine1.

FIG. 8shows a time line diagram in which the flow of lubricant is disrupted, leading to prolonged duration of only gas being detected. In the diagram ofFIG. 8, the alternation between lubricant and gas stops completely and the gas forces the lubricant out of the first conduit7such that a constant signal of only gas is being produced by the sensor3. The control unit6may be arranged to indicate this by performing an action such as alerting the user by the user interface13or by restricting power outlet of the engine1and eventually stopping the engine1.

InFIG. 9, the alternations between lubricant and oil are slower than what is determined to be acceptable, i.e. the one or both of t0and t1are not within their acceptable boundaries. This indicates that the flow of lubricant and/or gas past the sensor3is not functioning as intended which can be determined by the control unit6and which performs the action in response to the sensor3signal.

The engine1comprising the lubrication system according to the teachings herein is preferably be adapted for use in a power tool, such as a cut-off saw, lawn mover, chain saw, construction power tools or other similar tools suitable for being powered by an internal combustion engine.

The engine1may be 2-stroke or 4-stroke engine which may comprise a carburetor or fuel injection system. The throttle valve and/or the venturi may be comprised within a carburetor or fuel injector system and the first and second conduit7,8may therefore be connected directly to the carburetor or fuel injection system of the engine1.

It should be mentioned that the inventive concept is by no means limited to the embodiments described herein, and several modifications are feasible without departing from the scope of the invention as defined in the appended claims. For instance, the engine1may be used in other applications such as powering of vehicles.