Concepts To Reduce Architectural Complexity And Mass In Reciprocating

Abstract

The paper discusses some unconventional approaches to reducing the parts count and

complexity and simplifying the assembly process in reciprocating engines. This is expected to

become increasingly important against the present backdrop of increasing technology content of

passenger car engines (both gasoline and diesel) as the industry strives to meet ACEA

commitments on CO2 reduction in the near- to mid-term.

Some of these approaches permit the adoption of lighter materials such as magnesium and

aluminium in areas of the engine where they are not commonly employed, such as the crankcase

and the exhaust manifold, due to these areas being a normally unfavourable environment for

these materials. Also discussed is the use of bonding technology to reduce the number of noncritical

fasteners in the engine, and so to allow the overall package size to be reduced in both

mass and size, leading to important secondary benefits in-vehicle.

All of the concepts discussed have been individually proven on engines or in vehicle

construction and are complimentary such that, when combined, a new architecture concept

becomes attractive. This concept of a monoblock/integrated exhaust manifold assembly is

presented, together with a discussion of another potentially attractive architecture for the

modern world, the Burt-McCollum sleeve valve engine.