Patent Publication Number: US-9429049-B2

Title: Intake valve actuation system for dual fuel engine

Description:
TECHNICAL FIELD 
     The present disclosure relates generally to intake valve actuation (IVA) systems for dual fuel engines. More specifically, the present disclosure relates to an IVA system that is retrofittable between a dual fuel engine and a diesel fuel engine. 
     BACKGROUND 
     Diesel fuel engines are known to employ an intake valve actuation (IVA) system to actuate intake valves of the diesel fuel engine. The IVA system works in conjunction with an assembly of a cam lobe and a rocker arm, to actuate and maintain the intake valve in an open position during an intake stroke and a portion of a compression stroke of the diesel fuel engine. More specifically, the assembly of the cam lobe and the rocker arm actuates and maintains the intake valve in the open position during the intake stroke of the diesel fuel engine. Thereafter, an IVA piston of the IVA system pushes against the rocker arm, to lock the intake valves in the open position during a portion of the compression stroke. Notably, the IVA piston applies a push force against the rocker arm, to lock the intake valves in the open position. This push force on the rocker arm applies a reverse side force on the IVA piston, which may lead to component failure of the IVA piston. This reduces a service life of the IVA system. 
     Moreover, a hand-off is defined by the IVA system when the IVA piston pushes against the rocker arm of the IVA system. During a conventional hand-off between the cam lobe and the IVA piston, jerk motion is generally observed on the intake valves. This jerk motion may cause failure of various components of the IVA system, such as but not limited to, the intake valves, the IVA piston and/or the rocker arm. This leads to failure of the IVA system to actuate the intake valves. 
     Conventionally known IVA systems installed in the diesel fuel engine may be incompatible with dual fuel engines. A number of design changes may be required in both the conventional IVA system and the dual fuel engine, to install the conventional IVA systems on the dual fuel engine. This may be laborious and may increase the overall cost of the IVA system. In addition, once installed on the dual fuel engine, it may be cumbersome to re-install the IVA system on the dual fuel engine. Therefore, it is required that an IVA system be retrofitted between the diesel fuel engine and the dual fuel engine. 
     U.S. Pat. No. 5,479,896 discloses a compression release engine braking system (the IVA system) to transmit force and motion to open a valve of an internal combustion engine. Although, this reference discloses the compression release engine braking system to open the valve of the internal combustion engine, no reference provides the IVA system retrofittable between the dual fuel engine and the diesel fuel engine. 
     SUMMARY OF THE INVENTION 
     Various aspects of the present disclosure are directed towards an intake valve actuation (IVA) system for a dual fuel engine. The IVA system is retrofittable between the dual fuel engine and a diesel fuel engine. The dual fuel engine has at least one intake valve, a camshaft, and a rocker shaft. The rocker shaft has a central axis. The IVA system includes a cam lobe, a rocker arm, and an IVA piston. The cam lobe has a cam-profile. The rocker arm is rotatably mounted on the rocker shaft and has a pad surface. The pad surface includes a plane that passes through the central axis of the rocker shaft. The rocker arm is operably connected with the cam lobe and with the at least one intake valve. A rotational movement of the cam lobe corresponds to an oscillatory movement of the rocker arm, which correspondingly facilitates a switch between an open position and a closed position of the at least one intake valve. The IVA piston has a piston axis and a face portion. The face portion is arranged opposite to the pad surface of the rocker arm. The face portion selectively abuts and pushes against the pad surface, to restrict the oscillatory movement of the rocker arm and at least temporarily lock the at least one intake valve in the open position. Moreover, the IVA system defines a hand-off when the face portion of the IVA piston abuts against the pad surface of the rocker arm. In addition, the cam-profile facilitates a constant velocity of the at least one intake valve at the hand-off of the IVA system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of a portion of a dual fuel engine that illustrates intake valves and an intake valve actuation (IVA) system for the dual fuel engine, in accordance with the concepts of the present disclosure; 
         FIG. 2  is an enlarged view of a portion of the IVA system of  FIG. 1 , in accordance with the concepts of the present disclosure; 
         FIG. 3  is a perspective view of the IVA system of  FIG. 1  and  FIG. 2 , in accordance with the concepts of the present disclosure; 
         FIG. 4  is a side view of a cam lobe of the IVA system of  FIG. 1  and  FIG. 2  that illustrates a cam-profile of the cam lobe, in accordance with the concepts of the present disclosure; 
         FIG. 5  is a graph between a cam side lift of the intake valves and a crank angle, in accordance with the concepts of the present disclosure; 
         FIG. 6  is a graph between a cam side velocity of the intake valves and the crank angle, in accordance with the concepts of the present disclosure; 
         FIG. 7  is a graph between a cam side acceleration of the intake valves and the crank angle, in accordance with the concepts of the present disclosure; and 
         FIG. 8  is a graph between a cam side jerk motion of the intake valves and the crank angle, in accordance with the concepts of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIG. 1 , there is shown a portion of a dual fuel engine  10  for a machine (not shown). The machine (not shown) may embody a construction machine, a forest machine, a marine machine, and/or similar machines. As is customarily known, two fuels (for example a gaseous fuel and a diesel fuel) are selectively fed in a combustion chamber (not shown) of the dual fuel engine  10 , to produce power required to run the machine (not shown). In an embodiment of the present disclosure, the dual fuel engine  10  is a four-stroke engine in which a piston (not shown) completes four strokes (an intake stroke, a compression stroke, a combustion stroke, and an exhaust stroke) in one complete thermodynamic cycle. Notably, four strokes of the dual fuel engine  10  are defined relative to an angular orientation (crank angle) of a crankshaft (not shown) of the dual fuel engine  10 . Furthermore, the dual fuel engine  10  includes a camshaft  12 , a rocker shaft  14 , at least one intake valve  16 , and an intake valve actuation (IVA) system  18 . The IVA system  18  is adapted to actuate the intake valves  16  for crank angle corresponding to the intake stroke and at least a portion of the compression stroke of the dual fuel engine  10 . 
     In an embodiment of the present disclosure, the intake valves  16  may be two tappet valves supported in a cylinder head (not shown) of the dual fuel engine  10 . The intake valves  16  are adapted to operate in an open position and a closed position. In the open position, the intake valves  16  allow an air-fuel mixture to flow to the combustion chamber (not shown) of the dual fuel engine  10 . In the closed position, the intake valves  16  restricts the flow of the air-fuel mixture to the combustion chamber (not shown) of the dual fuel engine  10 . Although, the present disclosure contemplates tappet valves as the intake valve  16 , various other types of intake valves  16  may also be contemplated. 
     Referring to  FIG. 2 , there is shown a portion  20  of the dual fuel engine  10  that illustrates the IVA system  18  associated with the dual fuel engine  10 . The IVA system  18  is adapted to switch the intake valves  16  from the closed position to the open position. Moreover, the IVA system  18  maintains the intake valves  16  in the open position for a range of crank angles corresponding to the intake stroke and a portion of the compression stroke. In an embodiment of the present disclosure, the IVA system  18  includes a cam lobe  22  ( FIG. 1 ), a rocker arm  24 , and an IVA piston  26 . For clear understanding of the present disclosure, the cam lobe  22  is not shown in  FIG. 2 . 
     As is best seen in  FIG. 1 , the cam lobe  22  is fixedly mounted on the camshaft  12  and is adapted to rotate along with the camshaft  12 . The cam lobe  22  includes a cam-profile  28 , which is substantially oval shaped. The cam-profile  28  of the cam lobe  22  enables the opening and closing of the intake valves  16  via the rocker arm  24 , when rotated by the camshaft  12 . 
     The rocker arm  24  is rotatably mounted on the rocker shaft  14  of the dual fuel engine  10  and includes a pad surface  30 , a cam attachment end  32 , and a valve attachment end  34 . The pad surface  30  of the rocker arm  24  is in a plane, Y that passes through a central axis C-C′ of the rocker shaft  14 . The cam attachment end  32  of the rocker arm  24  is connected to the cam lobe  22  of the IVA system  18  via the follower link  36 . The valve attachment end  34  of the rocker arm  24  is connected to the intake valves  16  of the dual fuel engine  10  via a bridge member  38 . Therefore, a rotational movement of the cam lobe  22  corresponds to an oscillatory movement of the rocker arm  24 , which correspondingly facilitates a switch between the open position and the closed position of the intake valves  16 . 
     Furthermore, it may be noted that the cam-profile  28  of the cam lobe  22  is structured, such that the cam lobe  22  maintains the intake valves  16  in the open position during the intake stroke. Once the intake stroke is completed, the cam lobe  22  attempts to switch the intake valves  16  to the closed position. However, for better operational efficiency of the dual fuel engine  10 , the intake valves  16  are maintained in the open position for crank angles corresponding to a portion of the compression stroke, with use of the IVA piston  26 . 
     The IVA piston  26  may be a hydraulic piston that includes a piston axis X-X′ and a face portion  40 . The IVA piston  26  is mounted on the cylinder head (not shown) of the dual fuel engine  10 , such that the face portion  40  is arranged opposite to the pad surface  30  of the rocker arm  24 . More specifically, the face portion  40  of the IVA piston  26  abuts against the pad surface  30  of the rocker arm  24 . In this position, the piston axis X-X′ is perpendicular to the pad surface  30  of the rocker arm  24 . Further, the IVA piston  26  is adapted to selectively operate in a retracted position and an extended position. In the retracted position, the IVA piston  26  is inactive and the rocker arm  24  oscillates corresponding to the rotary movement of the cam lobe  22 . In the extended position, the face portion  40  abuts and pushes against the pad surface  30 , to restrict the oscillatory movement of the rocker arm  24  and at least temporarily lock the intake valves  16  in the open position. 
     Referring to  FIG. 3 , there is shown a perspective view of the IVA system  18  that better illustrates an arrangement of the IVA piston  26  with the rocker arm  24  of the IVA system  18 . The IVA piston  26  may be hydraulically actuated, to switch from the retracted position to the extended position. The IVA system  18  defines a hand-off, when the IVA piston  26  switches from the retracted position to the extended position. The hand-off refers to an instance when a control of the intake valves  16  is transferred from the cam lobe  22  to the IVA piston  26 . Although the present disclosure discloses the IVA piston  26 , which is hydraulically actuated, it can be understood by a person skilled in the art that the IVA piston  26  can be actuated by any another means know in the art. 
     Referring to  FIG. 4 , there is shown the cam lobe  22  of the IVA system  18 . The cam lobe  22  includes the cam-profile  28  defined by a base circle  42 , a maximum lift, L, and a cam axis B-B′. The cam lobe  22  rotates about a center, M of the base circle  42  and a cam side lift of the cam lobe  22  may vary as the cam lobe  22  rotates. Further, the cam lobe  22  includes the cam-profile  28  that facilitates opening and closing of the intake valves  16 . It may be contemplated that a lift, a velocity, and an acceleration of the intake valves  16  during opening and closing of the intake valves  16  is dependent on the cam-profile  28  of the cam lobe  22 . In an embodiment of the present disclosure, the cam-profile  28  is suitably structured, such that the cam-profile  28  facilitates constant velocity of the intake valves  16  at the hand-off of the IVA system  18 . This eliminates acceleration and jerk motion of the intake valves  16  at the hand-off. 
     Referring to  FIG. 5 ,  FIG. 6 ,  FIG. 7 , and  FIG. 8 , there is shown a graphical representation of various cam side parameters (cam side lift, cam side velocity, cam side acceleration, and cam side jerk motion) of the intake valves  16  at different crank angles of the dual fuel engine  10 . Notably, these cam side parameters (cam side lift, cam side velocity, cam side acceleration, and cam side jerk motion) correspond to actual parameters (lift, velocity, acceleration, and jerk motion) of the intake valves  16 . More specifically, the lift, the velocity, the acceleration, and the jerk motion, respectively of the intake valves  16 , is given by multiplication of the cam side lift, the cam side velocity, the cam side acceleration, and the cam side jerk motion with a rocker arm ratio. The IVA system  18  defines the hand-off when the face portion  40  of the IVA piston  26  abuts and pushes against the pad surface  30  of the rocker arm  24 . As is already mentioned, the hand-off is an instance when the control of the intake valves  16  is transferred from the cam lobe  22  to the IVA piston  26 . The hand-off initiates when the face portion  40  initially abuts against the pad surface  30  and ends when the control of the intake valves  16  is transferred to the IVA piston  26 . It may be noted that the hand-off may occur in a range 44 of 543 degree crank angles to 546 degree crank angles. It can be further understood that the hand-off can vary depending on the compression ratio requirements and piston to valve clearance of the dual fuel engine  10 . 
     Referring to  FIG. 5 , there is shown a graph that represents the cam side lift of the intake valve  16  relative to the crank angle of the dual fuel engine  10 . The crank angle of the dual fuel engine  10  is depicted on the abscissa axis and the cam side lift of the intake valves  16  is depicted on the ordinate axis. Notably, the cam side lift of the intake valves  16  is a deviation of the cam lobe  22  relative to the base circle  42  of the cam lobe  22 . The cam side lift of the intake valves  16  at 543 degree crank angles is 2.176 mm and at 546 degree crank angle is 2.311 mm. Moreover, the lift (actual) of the intake valves  16  is a displacement of a head of the intake valves  16  from a seated state in the closed position to an extended state in the open position. It may be contemplated that the lift (actual) of the intake valves  16  is given by multiplication of the cam side lift and the rocker arm ratio. 
     Referring to  FIG. 6 , there is shown a graph that represents the cam side velocity of the intake valves  16  relative to the crank angle of the dual fuel engine  10 . The crank angle of the dual fuel engine  10  is depicted on the abscissa axis and the cam side velocity of the intake valves  16  is depicted on the ordinate axis. Notably, the cam side velocity is a first derivative of the cam side lift of the intake valves  16 . The cam side velocity of the intake valves  16  at 543 degree crank angle is 0.19 mm/cam degree. The cam side velocity of the intake valves  16  at 546 degree crank angle is 0.19 mm/cam degree. Moreover, the velocity of the intake valves  16  is the actual velocity defined as change in the lift of the intake valves  16  for one degree rotation of the cam lobe  22 . It may be contemplated that the velocity (actual) of the intake valves  16  is given by multiplication of the cam side velocity and the rocker arm ratio. Therefore, the cam side velocity and the velocity of the intake valves  16  are constant at the hand-off of the IVA system  18 . 
     Referring to  FIG. 7 , there is shown a graph that represents the cam side acceleration of the intake valves  16  relative to the crank angle of the dual fuel engine  10 . The crank angle of the dual fuel engine  10  is depicted on the abscissa axis and the cam side acceleration of the intake valves  16  is depicted on the ordinate axis. Notably, the cam side acceleration is a first derivative of the cam side velocity of the intake valves  16 . The cam side acceleration of the intake valves  16  at 543 degree crank angle is 0 mm/square cam degree. The cam side acceleration of the intake valves  16  at 546 degree crank angle is 0 mm/square cam degree. Moreover, the acceleration of the cam lobe  22  is defined as change in the velocity of the intake valves  16  for one degree rotation of the cam lobe  22 . It may be contemplated that the acceleration (actual) of the intake valves  16  is given by multiplication of the cam side acceleration and the rocker arm ratio. Therefore, the cam side acceleration and the acceleration of the intake valves  16  at the hand-off is 0 mm/square cam degree. 
     Referring to  FIG. 8 , there is shown a graph that represents the cam side jerk motion of the cam lobe  22  applied on the rocker arm  24  relative to the crank angle of the dual fuel engine  10 . The crank angle of the dual fuel engine  10  is depicted on the abscissa axis and the cam side jerk motion of the intake valves  16  is depicted on the ordinate axis. Notably, the cam side jerk motion is a first derivative of the cam side acceleration of the intake valves  16 . Similar to the cam side acceleration, the cam side jerk motion at 543 degrees crank angle and 546 degree crank angle is 0 mm/cubic cam degree. It may be contemplated that the jerk motion (actual) of the intake valves  16  is given by multiplication of the cam side jerk motion and the rocker arm ratio. Therefore, the cam side jerk motion and the jerk motion of the intake valves  16  at the hand-off is zero. This facilitates a smooth transfer of control of the intake valves  16  from the cam lobe  22  to the IVA piston  26 . 
     INDUSTRIAL APPLICABILITY 
     In operation, the crankshaft (not shown) of the dual fuel engine  10  rotates the camshaft  12 , via a pulley and belt arrangement (not shown) or by means of a gear and pinion arrangement (not shown), for example. As the cam lobe  22  is attached to the camshaft  12 , a consequent rotation of the cam lobe  22  is attained. This rotational movement causes an oscillatory movement of the rocker arm  24  and corresponding opening and closing of the intake valves  16 . The cam-profile  28  of the cam lobe  22  enables the intake valves  16  to be in the open position for a range of crank angles that correspond to the intake stroke of the dual fuel engine  10 . Before the intake valves  16  is switched to the closed position, the IVA piston  26  is actuated from the retracted position to the extended position. In the extended position, the face portion  40  of the IVA piston  26  abuts and pushes against the pad surface  30  of the rocker arm  24  and restricts an immediate closure of the intake valve  16 . This enables the intake valves  16  to be locked in the open position temporarily. Effectively, the intake valves  16  are maintained in the open position for crank angles that correspond to a portion of the compression stroke. 
     It may be noted that the pad surface  30  of the rocker arm  24  is in the plane, Y that passes through the central axis C-C′ of the rocker shaft  14  and the piston axis X-X′ is perpendicular to the pad surface  30  of the rocker arm  24 . This facilitates a force on the pad surface  30  in a direction perpendicular to the pad surface  30  of the rocker arm  24 . Therefore, no reverse side force is applied on the IVA piston  26 , which increases life of the IVA system  18 . 
     Moreover, the cam-profile  28  of the cam lobe  22  facilitates a constant velocity of the intake valves  16  at the hand-off of the IVA system  18 . This facilitates zero acceleration at the hand-off and therefore no jerk motion is observed on the components of the IVA system  18 , such as but not limited to, the intake valves  16 , the rocker arm  24  and the IVA piston  26 . A jerk less operation of the cam lobe  22  increases life of the IVA system  18 . 
     Furthermore, the IVA system  18  as described in the present disclosure enables the opening and closing of the intake valves  16  for crank angles that correspond to the intake stroke and a portion of the compression stroke of the dual fuel engine  10 . However, the present disclosure is explained with the IVA system  18  applied to the dual fuel engine  10 , it may be noted that the concepts of the present disclosure may also be applied to a diesel fuel engine. More specifically, the IVA system  18  of the dual fuel engine  10  may be installed on a conventional diesel fuel engine. This may be accomplished by retrofitting the IVA system  18  (the cam lobe  22 , the rocker arm  24 , and the IVA piston  26 ) on to a conventional diesel fuel engine. The retrofittable IVA system  18  thereby facilitates the conversion of a conventional diesel engine into a duel fuel engine. 
     It should be understood that the above description is intended for illustrative purposes only and is not intended to limit the scope of the present disclosure in any way. Those skilled in the art will appreciate that other aspects of the disclosure may be obtained from a study of the drawings, the disclosure, and the appended claim.