Internal combustion engine

Abstract: A small four-cycle aluminium internal combustion engine (30) comprises a crankshaft (36), which is journaled to the engine block for rotation about a crankshaft axis. A piston (38) reciprocates within the bore (34) and is connected to the crankshaft by a connecting rod (40) having oil splasher (60) formed thereon for intermittently engaging the oil within the enclosed oil reservoir (58) to splash lubricate the engine. The engine (30) is provided with a cylinder head (42) assembly defining a compact combustion chamber (44) having a pair of overhead intake exhaust ports (46, 52) cooperating intake and exhaust valves (50, 56). A lightweight high powered engine (30) is thereby provided having relatively low HC and CO emissions.

Description: This invention relates to a small four-cycle internal combustion engine. Portable operator carried power tools such as line trimmers, blower/vacuums, or chain saws are currently powered by two-cycle internal combustion engines or electric motors. With the growing concern regarding air pollution, there is increasing pressure to reduce the emissions of portable power equipment. Electric motors unfortunately have limited applications due to power availability for corded products and battery life for cordless devices. In instances where weight is not an overriding factor such as lawn mowers, emissions can be dramatically reduced by utilizing heavier four-cycle engines. When it comes to operator carried power tools such as line trimmers, chain saws and blower/vacuums, four-cycle engines pose a very difficult problem. Four-cycle engines tend to be too heavy for a given horsepower output and lubrication becomes a very serious problem since operator carried power tools must be able to run in a very wide range of orientations. The California Resource Board (CARB) in 1990 began to discuss with the industry, particularly the Portable Power Equipment Manufacturer's Association (PPEMA), the need to reduce emissions. In responding to the CARB initiative, the PPEMA conducted a study to evaluate the magnitude of emissions generated by two-cycle engines in an effort to determine whether they were capable of meeting the proposed preliminary CARB standards tentatively scheduled to go into effect in 1994. The PPEMA study concluded that at the present time, there was no alternative power source to replace the versatile lightweight two-stroke engine currently used in hand held products. Four-cycle engines could only be used in limited situations, such as in portable wheeled products like lawn mowers or generators, where the weight of the engine did not have to be borne by the operator. US-A-4,286,675 discloses a portable operator carried power tool having a frame to be carried by an operator, an implement co-operating with the frame and having a rotary driven input member and an internal combustion engine attached to the frame and provided with an output member coupled to the implement input member. US-A-4,404,936 discloses as prior art a four-cycle engine having a breather device, which is lubricated by means of an oil mist. The oil mist circulates with the movement of blow-by gas. It is an object of the present invention to provide an internal combustion engine which can achieve high power output and relatively low exhaust emissions, which is sufficiently light to be carried by an operator, and which has an internal lubrication system enabling the engine to be run at a wide variety of orientations typically encountered during normal operation. It is a further object of the present invention to provide a small lightweight four-cycle engine having an aluminium engine block, an overhead valve train and a lubrication system for generating an oil mist to lubricate the crank case throughout a range of operating positions. It is yet a further object of the invention to provide an oil mist pumping system to pump the oil mist generated into the overhead valve chamber. These objects and other features and advantages of the present invention will be apparent upon further review of the remainder of the specification and the drawings. In accordance with the present invention there is provided a four-cycle internal combustion engine comprising: an engine block defining a cylindrical bore, a cylinder head, a piston mounted for reciprocation in said cylindrical bore, said cylinder head defining a combustion chamber; an air-fuel mixture intake port and an exhaust gas port defined in said cylinder head assembly; a valve cover on said cylinder head defining a valve chamber; intake and exhaust valves mounted in said intake and exhaust ports, respectively, for reciprocation between port-open and port-closed positions; a valve-actuating valve train, said valve train including at least one rocker arm and at least one valve train push rod assembly extending at one end thereof within said valve chamber and engaging said rocker arm; a crankshaft rotatably mounted in said engine block including a crankpin and a counterweight; a connecting rod assembly having at one end thereof articulated connections to said piston and at the opposite end thereof to said crank portion thereby forming a piston-connecting rod crankshaft assembly; a cam rotatably driven by said crankshaft and driven at one-half crankshaft speed, the opposite ends of said push rod assembly being drivably connected to said cam whereby said push rod assembly is actuated with a reciprocating motion upon rotation of said cam; an oil reservoir; an oil mist generator element connected drivably to said crankshaft to engage the lubrication oil in order to create an oil mist in said reservoir which lubricates moving parts within the engine block, said reservoir being in fluid communication with said cylindrical bore whereby pressure within the oil reservoir fluctuates as the piston reciprocates; passageways extending between said reservoir and said valve chamber, to allow the flow of said oil mist through said passages to lubricate the valve train; and characterised by the provision of an oil mist flow control system for actively controlling the circulation of oil mist from said reservoir to said valve chamber and back from said valve chamber to said reservoir via said passageways, said flow control system including a valve operable in synchronisation with increases and decreases in gas pressure in said engine block below said piston as said piston reciprocates in said cylindrical bore for controlling the direction of the oil mist circulation. Figure 1 is a perspective view illustrating a line trimmer incorporating a four-cycle engine; Figure 2 is a cross-sectional side elevation of an engine incorporating a known type of lubrication system taken along line 2.2 of Figure 1; Figure 3 is a side cross-sectional elevational view of the engine of Figure 2; Figure 4 is an enlarged schematic illustration of the cam shaft and the follower mechanism of the engine of Figure 2; Figure 5 is a cross-sectional side elevational view of an embodiment of an engine according to the present invention. Figure 6 is an enlarged cross-sectional view of the engine embodiment of Figure 7 illustrating the lubrication system; Figure 7 is a partial cross-sectional end view of the engine embodiment shown in Figure 5 and 6 further illustrating the lubrication system; Figure 8 is a timing diagonal of the lubrication system of the engine embodiment; Figure 9 is a torque versus RPM curve; and Figure 10 and Figure 11 contrast the pull force of a four and a two-cycle engine. Figure 1 illustrates a line trimmer 20 suitable for incorporating a four-cycle engine made in accordance with the present invention. Line trimmer 20 is used for illustration purposes and it should be appreciated that other power tools, especially those tended to be carried by operators such as chain saws or a blower vacuum, can be made in a similar fashion. Line trimmer 20 has a frame 22 which is provided by an elongated aluminum tube. Frame 22 has a pair of handles 24 and 26 to be grasped by the operator during normal use. Strap 28 is placed over the shoulder of the user in a conventional manner in order to more conveniently carry the weight of the line trimmer during use. Attached to one end of the frame generally behind the operator is a four-cycle engine 30. The engine drives a conventional flexible shaft which extends through the center of the tubular frame to drive an implement 32 having a rotary cutting head or the like affixed to the opposite end of the frame. It should be appreciated that in the case of a chain saw or a blower/vacuum, the implement would be a cutting chain or a rotary impeller, respectively. Figure 2 illustrates a cross-sectional end view of a four-cycle engine 30 having a known lubrication system. Four-cycle engine 30 is made up of a lightweight aluminium block 32 having a cylindrical bore 34 formed therein. Crankshaft 36 is pivotably mounted within the engine block in a conventional manner. Piston 38 slides within the cylindrical bore 34 and is connected to the crankshaft by connecting rod 40. A cylinder head 42 is affixed to the engine block to define an enclosed combustion chamber 44. Cylinder head 42 is provided with an intake port 46 coupled to a carburetor 48 and selectively connected to the combustion chamber 44 by intake valve 50. Cylinder head 42 is also provided with an exhaust port 52 connected to muffler 54 and selectively connected to combustion chamber 44 by exhaust valve 56. As illustrated in Figures 2 and 3, the cylinder axis of four-cycle engine 30 is generally upright when in normal use. Engine block 32 is provided with an enclosed oil reservoir 58. The reservoir is relatively deep so that there is ample clearance between the crankshaft and the level of the oil during normal use. As illustrated in Figure 2, the engine may be rotated about the crankshaft axis plus or minus an angle β before the oil level would rise sufficiently to contact the crankshaft. Preferably, β is at least above 30° and most preferably at least 45° in order to avoid excessive interference between the crankshaft and the oil within the oil reservoir. As illustrated in a cross-sectional side elevation shown in Figure 3, the engine shown in its vertical orientation would typically be used in a line trimmer canted forward 20° to 30°. As illustrated, the engine can be tipped fore and aft plus or minus an angle α without the oil within the reservoir striking the crankshaft. Again, preferably the angle α is at least above 30° viewing the engine in side view along the transverse axis orthogonal to the axes of the engine crankshaft 36 and the cylinder bore 34. In order to lubricate the engine, connecting rod 40 is provided with a splasher portion 60 which dips into the oil within the reservoir with each crankshaft revolution. The splasher 60 creates an oil mist which lubricates the internal moving parts within the engine block. As illustrated in Figure 3, the crankshaft 36 is of a cantilever design similar to that commonly used by small two-cycle engines. The crankshaft is provided with an axial shaft member 62 having an output end 64 adapted to be coupled to the implement input member and input end 66 coupled to a counterweight 68. A crankpin 70 is affixed to counterweight 68 and is parallel to and radially offset from the axial shaft 62. Crankpin 70 pivotally cooperates with a series of roller bearings 72 mounted in connecting rod 40. The axial shaft 62 of crankshaft 36 is pivotably attached to the engine block 32 by a pair of conventional roller bearings 74 and 76. Intermediate roller bearings 74 and 76 is camshaft drive gear 78. The camshaft drive and valve lifter mechanism is best illustrated with reference to figures 3 and 4. Drive gear 78 which is mounted upon the crankshaft drives cam gear 80 which has twice the diameter resulting in the camshaft rotating at one-half engine speed. Cam gear 80 is affixed to the camshaft assembly 82 which is journaled to engine block 32 and includes a rotary cam lobe 84. In the engine illustrated, a single cam lobe is utilized for driving both the intake and exhaust valves, however, a conventional dual cam system could be utilized as well. Cam lobe 84 as illustrated in Figure 4, operates intake valve follower 86 and intake push rod 88 as well as exhaust valve follower 90 and exhaust push rod 92. Followers 86 and 90 are pivotably connected to the engine block by pivot pin 93. Push rods 88 and 92 extend between camshaft followers 86 and 90 and rocker arms 94 and 96 located within the cylinder head 42. Affixed to the cylinder head 42 is a valve cover 98 which defines therebetween enclosed valve chamber 100. A pair of push rods guide tubes 102 surround the intake and exhaust push rods 88 and 92 in a conventional manner in order to prevent the entry of dirt into the engine. The illustrated four-cycle engine 30 has a sealed valve chamber 100 which is isolated from the engine block and provided with its own lubricant. Preferably, valve chamber 100 is partially filled with a lightweight moly grease. Conventional valve stem seals, not shown, are provided in order to prevent escape of lubricant. Engine 30 operates on a conventional four-cycle mode. Spark plug 104 is installed in a spark plug hole formed in the cylinder head so as to project into the enclosed combustion chamber 44. The intake charge provided by carburetor 48 will preferably have an air fuel ratio which is slightly lean stoichiometric, i.e. having an air fuel ratio expressed in terms for stoichiometric ratio which is not less than 1.0. It is important to prevent the engine from being operated rich as to avoid a formation of excessive amounts of hydrocarbon (HC) and carbon monoxide (CO) emissions. Most preferably, the engine will operate during normal load conditions slightly lean of stoichiometric in order to minimize the formation of HC, CO and oxides of nitrogen (NOx). Running slightly lean of stoichiometric air fuel ratio will enable excess oxygen to be present in the exhaust gas thereby fostering post-combustion reduction of hydrocarbons within the muffler and exhaust port. For use in a line trimmer of the type illustrated in Figure 1, adequate power output of a small lightweight four-cycle engine is achievable utilizing an engine with a displacement less than 80cc. Preferably, engines for use in the present invention will have a displacement falling within the range of 20 and 60 cc. Engines of displacement larger than 80cc will result in excessive weight to be carried by an operator. Engines of smaller displacement will have inadequate power if operated in such a manner to maintain low emission levels. In order to achieve high power output and relatively low exhaust emissions, four-cycle engine 30 is provided with a very compact combustion chamber 44 having a relatively low surface to volume ratio. In order to maximise volumetric efficiency and engine output for relatively small engine displacement, canted valves shown in Figure 2 are used resulting in what is commonly referred to as a hemispherical-type chamber. Intake and exhaust ports 46 and 52 are oriented in line and opposite one another resulting in a cross flow design capable of achieving very high horsepower relative to engine displacement compared to a typical four-cycle lawn mower engine having a flat head and a valve-in-block design. Figures 5-8 illustrate an embodiment of an engine 150 according to the present invention with an improved system for lubricating overhead valves. Engine 150 has an engine block with a single cam and dual follower design generally similar to that of Figures 2 and 3 and described previously. Cylinder head 152 is provided with a valve cover 154 to define enclosed valve chamber 156 therebetween. Valve chamber 156 is coupled to oil reservoir 158 within the engine block. In order to induce the mist ladened air within the oil reservoir 158 to circulate through valve chamber 156, flow control means is provided for alternatively selectively coupling the valve chamber to the oil reservoir via one of a pair of independent fluid passageways. As illustrated in Figures 6 and 7, intake push rod tube 160 provides a first passageway connecting the oil reservoir to the valve chamber, while exhaust push rod tube 162 provides a second independent passageway connecting the valve chamber 156 to the oil reservoir 158. As illustrated in Figure 6, port B connects push rod tube 162 to the cylindrical bore 166. Port B intersects the cylindrical bore at a location which is swept by the skirt of piston 168 so that the port is alternatively opened and closed in response to piston movement. Camshaft 170 and support shaft 172 are each provided with a pair of ports A which are selectively coupled and uncoupled once every engine revolution, i.e., twice every camshaft revolution. When the ports are aligned, the oil reservoir is fluidly coupled to the valve chamber via the intake push rod tube 160. When the ports are misaligned, the flow path is blocked. Figure 8 schematically illustrates the open and closed relationship for the A and B ports relative to crankcase pressure. When the piston is down and the crankcase is pressurized, the A port is open allowing mist ladened air to flow through the passageway within camshaft support shaft 172 through the intake push rod tube 160 and into the valve chamber 156. When the piston rises, the crankcase pressure drops below atmospheric pressure. When the piston is raised, the A port is closed and the B port is opened enabling the pressurized air valve chamber 156 to return to oil reservoir 158. Of course, other means for inducing the circulation of mist ladened air from the oil reservoir to the valve chamber can be used to obtain the same function, such as check valves or alternative mechanically operated valve designs. Having a loop type flow path as opposed to a single bi-directional flow path, more dependable supply of oil can be delivered to the valve chamber. It is believed that small lightweight four-cycle engines made in accordance with the present invention will be particularly suited to use with rotary line trimmers, as illustrated in Figure 1. Rotary line trimmers are typically directly driven. It is therefore desirable to have an engine with a torque peak in the 7000 to 9000 RPM range which is the range in which common line trimmers most efficiently cut. As illustrated in Figure 9, a small four-cycle engine of the present invention can be easily tuned to have a torque peak corresponding to the optimum cutting speed of a line trimmer head. This enables small horsepower engine to be utilized to achieve the same cutting performance as compared to a higher horsepower two-cycle engine which is direct drive operated. Of course, a two-cycle engine speed can be matched to the optimum performance speed of the cutting head by using a gear reduction, however, this unnecessarily adds cost, weight and complexity to a line trimmer. Another advantage to the four-cycle engine for use in a line trimmer is illustrated with reference to Figures 10 and 11. Figure 10 plots the starter rope pull force versus engine revolutions. The force pulses occur every other revolution due to the four-cycle nature of the engine. A two-cycle engine as illustrated in Figure 11 has force pulses every revolution. It is therefore much easier to pull start a four-cycle engine to reach a specific starting RPM since approximately half of the work needs to be expended by the operator. Since every other revolution of a four-cycle engine constitutes a pumping loop where there is relatively little cylinder pressure, the operator pulling starter rope handle 174 (shown in Figure 1) is able to increase engine angular velocity during the pumping revolution so that proper starting speed and sufficient engine momentum can be more easily achieved. The pull starter mechanism utilized with the four-cycle engine is of a conventional design. Preferably, the pull starter will be located on the side of the engine closest to the handle in order to reduce the axial spacing between trimmer handle 24 and the starter rope handle 174, thereby minimizing the momentum exerted on the line trimmer during start up. A four-cycle engine is particularly advantageous in line trimmers where, in the event the engine were to be shut off when the operator is carrying the trimmer, the operator can simply restart the engine by pulling the rope handle 174 with one hand and holding the trimmer handle 24 with the other. The reduced pull force makes it relatively easy to restart the engine without placing the trimmer on the ground or restraining the cutting head, as is frequently done with two-cycle line trimmers.

Claims: A four-cycle internal combustion engine (30) comprising: an engine block defining a cylindrical bore (34), a cylinder head (42), a piston (38) mounted for reciprocation in said cylindrical bore (34), said cylinder head (42) defining a combustion chamber (44); an air-fuel mixture intake port (46) and an exhaust gas port (52) defined in said cylinder head assembly; a valve cover (98) on said cylinder head (42) defining a valve chamber (100); intake and exhaust valves (50, 56) mounted in said intake and exhaust ports (46, 52), respectively, for reciprocation between port-open and port-closed positions; a valve-actuating valve train (86-96), said valve train including at least one rocker arm (94) and at least one valve train push rod assembly (88) extending at one end thereof within said valve chamber (100) and engaging said rocker arm (94); a crankshaft (36) rotatably mounted in said engine block including a crankpin (70) and a counterweight (68); a connecting rod assembly (40) having at one end thereof articulated connections to said piston (38) and at the opposite end thereof to said crankpin (70) thereby forming a piston-connecting rod crankshaft assembly; a cam (84) rotatably driven by said crankshaft (36) and driven at one-half crankshaft speed, the opposite ends of said push rod assembly being drivably connected to said cam (84) whereby said push rod assembly (88) is actuated with a reciprocating motion upon rotation of said cam (84); an oil reservoir (58); an oil mist generator element (60) connected drivably to said crankshaft (36) to engage the lubrication oil in order to create an oil mist in said reservoir (58) which lubricates moving parts within the engine block, said reservoir (158) being in fluid communication with said cylindrical bore (34) whereby pressure within the oil reservoir (58) fluctuates as the piston (38) reciprocates; passageways (160, 162) extending between said reservoir (158) and said valve chamber (156), to allow the flow of said oil mist through said passages to lubricate the valve train (86-98); and characterised by the provision of an oil mist flow control system for actively controlling the circulation of oil mist from said reservoir (158) to said valve chamber (156) and back from said valve chamber (156) to said reservoir (158) via said passageways (160, 162), said flow control system including a valve operable in synchronisation with increases and decreases in gas pressure in said engine block below said piston (38) as said piston (38) reciprocates in said cylindrical bore (34) for controlling the direction of the oil mist circulation. An engine (150) as claimed in claim 1 wherein said driving connection between said cam (84) and said crankshaft (36) comprises a cam gear (80) driven by said crankshaft (36), said flow control system including said cam gear (80), a port (A) in said cam gear (80) registering with one of said passageways (160) whereby said one passageway (160) is alternately opened and closed during revolution of said cam (84). An engine (30) as claimed in any one of the preceding claims including at least one push rod guide tube (102) extending from said engine block to said cylinder head (42), a push rod (88) extending through said push rod guide tube (102); in which said guide tube (102) forms a closed oil mist passage. An engine (30) as claimed in any one of the preceding claims wherein said oil mist generator element (60) is integrally attached to said opposite end of said connecting rod (40). An engine (30) as claimed in any one of the preceding claims in which the valve-actuating valve train (86-96) includes a pair of rocker arms (94, 96) and a pair of push rod assemblies (88, 92). The engine (150) as claimed in any one of the preceding claims wherein said oil mist flow path extends through said engine (150) in order to lubricate said intake and exhaust valves (50, 56), said valve train (86-96), said crankshaft (36), said piston (36), and said cam (84). The engine (30) as claimed in any one of the preceding claims wherein said intake and exhaust ports (46, 52) are disposed in said cylinder head (42) at spaced locations in said combustion chamber and a spark plug opening disposed generally intermediate said intake and exhaust ports (46, 52) whereby an air fuel mixture is induced into said combustion chamber (44) in a cross flow fashion, and near stoichiometric combustion may be maintained at standard operating conditions throughout a wide range of throttle settings. The engine (30) as claimed in any one of the preceding claims in which the displacement of the engine is 80cc or less. A method for lubricating a four-cycle internal combustion engine (30), the engine having an engine block, a reciprocating piston (38) in a cylindrical bore (34) in the engine block, a crankshaft (36), a cam (84), a cam gear (80), a valve actuating valve train (86-96), a pair of rocker arms (94, 96), an oil reservoir (58) and a cylindrical head (42) having a valve cover (98) defining a valve chamber (100) and intake and exhaust valves (50, 56), the method comprising the steps of: creating within said oil reservoir (58) an oil mist; providing said oil mist to lubricate said piston (38), said crankshaft (36), said cam (84), said cam gear (80), said pair of rocker arms (94, 96); the oil mist being further provided to said valve train (86-96) and said intake and exhaust valves (50, 56) by conducting the oil mist between said reservoir (158) and the valve chamber (156) via passageways (160, 162); characterised by the step of actively controlling the circulation of oil mist from said reservoir (158) to said valve chamber (156) and back to said reservoir via said passageways by means of a valve operating in synchronism with increases and decreases in gas pressure in said engine block below said piston (38) as said piston reciprocates in said cylindrical bore (34) to control the direction of the oil mist circulation.

Inventors: EVERTS ROBERT G, KURIHARA KATSUMI, EVERTS, ROBERT G., KURIHARA, KATSUMI
Applicants: RYOBI NORTH AMERICA INC, RYOBI NORTH AMERICA, INC.
Application year: 1992
Main classification: F01M9
IPC codes: F02B75, F02B63, F01M9, F01M1