The invention pertains to lightweighting engine components such as the cylinder head, connecting rod, and cylinder liner in an internal combustion engine. This technology aims to reduce the overall weight of the engine, thus enhancing fuel efficiency and reducing emissions. By redesigning these components to be manufacturable using sheet metal, significant weight reduction is achieved while maintaining performance.
Figure (1) Sheet metal piston; (2) Energy comparison during manufacturing; (3) Fuel saving
The increasing number of vehicles has led to a higher demand for fuel, making fuel consumption a critical issue. Traditional methods have focused on lightweighting autobodies, but there is a need to reduce the weight of engine components to further enhance fuel efficiency and reduce emissions.
- Weight reduction: This innovation achieves up to a 25% reduction in weight for components such as the connecting rod.
- Material selection: It uses materials like Al-SiC, pure aluminum, and aluminum alloys for high thermal conductivity and lightweight properties.
- Redesign of engine components: Components such as the cylinder head, connecting rod, and cylinder liner have been redesigned using sheet metal.
- Enhanced fuel efficiency: Lighter engine components contribute to lower fuel consumption and reduced emissions.
- Cooling system: Integrated fins and liquid-filled gaps enhance engine cooling efficiency without the need for additional radiators.
- Manufacturing techniques: It utilizes processes such as drawing, welding, and Metal Injection Molding (MIM) for manufacturing the components.
- Cost-effective manufacturing: The use of sheet metal and advanced manufacturing processes reduces material and production costs.
Prototypes include redesigned connecting rods, piston heads, and cylinder liners. These prototypes have been tested to ensure they meet the required performance standards under both static and dynamic conditions.
The technology has been developed and prototyped, demonstrating significant weight reduction and performance improvements in engine components. Further refinement and large-scale manufacturing adaptations are underway.
3
The adoption of this technology can lead to a significant reduction in fuel consumption and emissions from vehicles, contributing to environmental conservation and sustainability. It also supports the automotive industry in meeting stringent regulatory standards for fuel efficiency and emissions.
- Automotive Industry: It is primarily for use in internal combustion engines of vehicles to improve fuel efficiency and reduce emissions.
- Hybrid and Electric Vehicles: Lightweight components can also be beneficial in hybrid and electric vehicle engines to improve overall efficiency.
201621036366
504623