Internal combustion engine and method of making the same

• US 6,595,167 B2
• Filed: 08/24/2001
• Issued: 07/22/2003
• Est. Priority Date: 05/22/2001
• Status: Expired due to Fees

• Current Assignee: Mtd Products Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Mtd Products Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Kaesgen, Hartmut
• Primary Examiner(s): Argenbright, Tony M.
• Assistant Examiner(s): Harris, Katrina B.
• Application Number:
  US09/939,168
• Publication Number:
  US 20020189570A1
• Time in Patent Office: 697 Days
• Field of Search: 123/55.2, 123/197.4, 123/90.61, 123/48.C, 123/78.C
• US Class Current: 123/55.2
• CPC Class Codes: F01B 1/12 Separate cylinder-crankcase elements coupled together to form a unit
• CPC Class Codes: F02B 2075/1808 two
• CPC Class Codes: F02B 75/243 with only one crankshaft of the "boxer" type, e.g. all connecting rods attached to separate crankshaft bearings

Abstract

A modular engine design system utilizes selectively replaceable components whereby a family of related engines having varying power outputs may be produced. A first series of engines utilizes a common piston operable in a cylinder of first predetermined dimensions. The engine design may utilize a first or second crankshaft/connecting rod combination to vary the power output. A modified engine design utilizes a second cylinder in addition to the first cylinder. A second series of engines utilizes a larger piston operable in a cylinder of second predetermined dimensions. The second series of engines shares a common engine design scheme with the first series of engines. However, corresponding parts are adapted for use with the larger piston/cylinder combination. The second series of engines may likewise utilize a first or second crankshaft/connecting rod combination to vary the power output.

Claims

1. A modular engine design system for providing a plurality of related engines, wherein each engine includes at least one cylinder block defining a cylinder therein, a crankcase having an opening therein communicating with the cylinder, a piston adapted for reciprocal movement in the cylinder, a crankshaft adapted for rotational movement within the crankcase, a connecting rod interconnecting the piston and the crankshaft, and a camshaft operably associated with the crankshaft and being operable to selectively operate a valve assembly associated with the cylinder block, the modular engine design system comprising:

a first engine design for providing a basic engine associated with a first power output, said basic engine being formed of selectively replaceable basic engine components, wherein said basic engine components include;

a first cylinder block defining a first cylinder therein having first predetermined physical dimensions,

a first crankcase,

a first piston, said piston having first predetermined dimensions,

a first camshaft,

a first connecting rod having a length L₁,

a first crankshaft, said first crankshaft and said first connecting rod operably defining a first piston stroke;

a second engine design for providing a second engine related to said basic engine wherein said second engine is associated with a second power output, said second power output being substantially different than said first power output and wherein said second engine design utilizes;

said first cylinder block defining said first cylinder therein having said first predetermined physical dimensions,

said first crankcase,

said first piston,

said first camshaft,

a second connecting rod having a length L₂, wherein L₂ differs from L₁, said second connecting rod selectively replacing said first connecting rod, and

a second crankshaft, said second crankshaft selectively replacing said first crankshaft, said second crankshaft and said second connecting rod operably defining a second piston stroke substantially different from said first piston stroke;

a third engine design for providing a third engine related to said basic engine wherein said third engine is associated with a third power output, said third power output being substantially different from said first power output and said second power output, wherein said third engine design utilizes;

two of said first cylinder blocks each defining said first cylinder therein having said first predetermined physical dimensions,

two of said first pistons,

two of said first connecting rods wherein each first connecting rod is operably associated with a different one of said first pistons;

a modified crankcase, said modified crankcase selectively replacing said first crankcase, said modified crankcase having two openings therein, each of said openings communicating with a different one of said first cylinders;

a third crankshaft, said third crankshaft selectively replacing said first crankshaft, said third crankshaft and said first connecting rods operably defining third piston strokes for each of said first pistons of said third engine wherein said third piston strokes are substantially equal to said first piston stroke of said basic engine;

a modified camshaft being operable to selectively operate two of said valve assemblies, each of said valve assemblies being associated with a different one of said first cylinder blocks, said modified camshaft selectively replacing said first camshaft; and

,

a fourth engine design for providing a fourth engine related to said basic engine wherein said fourth engine is associated with a fourth power output, said fourth power output being substantially different than said first power output and wherein said fourth engine design utilizes;

two of said first cylinder blocks each defining said first cylinder therein having said first predetermined physical dimensions,

two of said first pistons,

two of said second connecting rods wherein each second connecting rod is operably associated with a different one of said first pistons,

said modified crankcase, said modified crankcase selectively replacing said first crankcase, wherein each of said openings communicates with a different one of said first cylinders,

a fourth crankshaft, said fourth crankshaft selectively replacing said first crankshaft, said fourth crankshaft and said second connecting rods operably defining fourth piston strokes for each of said first pistons of said fourth engine wherein said fourth piston strokes are substantially equal to said second piston stroke of said second engine, and

said modified camshaft being operable to selectively operate two of said valve assemblies, each of said valve assemblies being associated with a different one of said first cylinder blocks, said modified camshaft selectively replacing said first camshaft.

2. A modular engine design system for providing a plurality of related engines, wherein each engine includes at least one cylinder block defining a cylinder therein, a crankcase having an opening therein communicating with the cylinder, a piston adapted for reciprocal movement in the cylinder, a crankshaft adapted for rotational movement within the crankcase, a connecting rod interconnecting the piston and the crankshaft, and a camshaft operably associated with the crankshaft and being operable to selectively operate a valve assembly associated with the cylinder block, the modular engine design system comprising:

a first engine design for providing a basic engine associated with a first power output, said basic engine being formed of selectively replaceable basic engine components, wherein said basic engine components include;

a first cylinder block defining a first cylinder therein having first predetermined physical dimensions,

a first crankcase,

a first piston, said piston having first predetermined dimensions,

a first camshaft,

a first connecting rod having a length L₁,

a first crankshaft, said first crankshaft and said first connecting rod operably defining a first piston stroke; and

,

a modified engine design for providing a modified engine shares a common design scheme with said basic engine by sharing a common design scheme wherein said modified engine is associated with a modified power output, said modified power output being substantially different than said first power output and wherein said modified engine design utilizes;

a modified cylinder block defining a modified cylinder therein having modified predetermined physical dimensions, wherein said modified predetermined physical dimensions are substantially different than said first physical predetermined dimensions of said first cylinder, said modified cylinder block selectively replacing said first cylinder block,

a modified crankcase, said modified crankcase selectively replacing said first crankcase,

a modified piston, said modified piston having modified predetermined dimensions, said modified piston selectively replacing said first piston,

a modified connecting rod having a length, L₃, said modified connecting rod selectively replacing said first connecting rod,

a modified crankshaft, said modified crankshaft selectively replacing said first crankshaft, said modified crankshaft and said modified connecting rod operably defining a modified piston stroke for said modified piston of said modified engine, and

a modified camshaft, said second modified camshaft selectively replacing said first camshaft.

3. A modular engine design system for providing a plurality of related engines, said modular engine design system comprising:

a first engine design for providing a basic engine, said basic engine being formed of selectively replaceable basic engine components wherein said basic engine components include;

a first cylinder block defining a first cylinder therein of first predetermined dimensions;

a first crankcase first and second substantially symmetrical portions, said first crankcase having an opening therein communicating with said first cylinder;

a first piston adapted for reciprocal movement in said first cylinder;

a first crankshaft adapted for rotational movement within the first crankcase;

a first connecting rod having a length, L₁, said first connecting rod operatively connecting said first piston to said first crankshaft; and

,

a first camshaft operably associated with said first crankshaft and being operable to selectively operate a valve assembly, wherein said basic engine is associated with a first power output; and

,

a second engine design for providing a second engine related to said basic engine, wherein at least one of said basic engine components is replaced with a corresponding modified engine component substantially different from said basic engine component, wherein said second engine is associated with a second power output being substantially different from said first power output.

4. The engine design system of claim 3 wherein said first piston is adapted for reciprocal movement along a piston axis and wherein said first crankcase is divided into first and second portions along a plane that is angled relative to said piston axis.

5. The engine design system of claim 3 wherein said first piston is adapted for reciprocal movement along a piston axis and wherein said first crankcase is divided into first and second portions along a plane that is substantially perpendicular to said piston axis.

6. A modular engine design system for providing a plurality of related engines, wherein each engine includes at least one cylinder block defining a cylinder therein, a crankcase having an opening therein communicating with the cylinder, a piston adapted for reciprocal movement in the cylinder, a crankshaft adapted for rotational movement within the crankcase, a connecting rod interconnecting the piston and the crankshaft, and a camshaft operably associated with the crankshaft and being operable to selectively operate a valve assembly associated with the cylinder block, the modular engine design system comprising:

a first engine design for providing a basic engine associated with a first power output, said basic engine being formed of selectively replaceable basic engine components, wherein said basic engine components include;

a first cylinder block/first piston combination, said first cylinder block defining a first cylinder therein having first predetermined physical dimensions, and said first piston having first predetermined dimensions,

a first crankcase,

a first camshaft,

a first crankshaft; and

,

a first connecting rod, said first connecting rod having a length L₁, said first crankshaft and said first connecting rod operably defining a first piston stroke;

a second engine design for providing a second engine related to said basic engine wherein said second engine is associated with a second power output, said second power output being substantially different than said first power output and wherein said second engine design utilizes;

a second first cylinder block/first piston combination;

a modified crankcase, said modified crankcase selectively replacing said first crankcase, said modified crankcase having a second opening therein being operably associated with said second first cylinder block/first piston combination;

a pair of first connecting rods, each of said connecting rods being associated with one of said first pistons; and

a modified crankshaft selectively replacing said first crankshaft, said modified crankshaft being operably associated with said pair of first connecting rods.

7. A method for manufacturing an engine having a predetermined power output utilizing an engine design system, wherein the engine design system provides engine components comprising a plurality of cylinder blocks, a plurality of pistons, a plurality of connecting rods, a plurality of crankcases, a plurality of crankshafts, and a plurality of camshafts, wherein a selection of engine components cooperate to provide said engine having said predetermined power output, the method comprising the steps of:

providing a first engine design for providing a basic engine, said basic engine being formed of selectively replaceable basic engine components wherein said basic engine components include;

a first cylinder block defining a first cylinder therein of first predetermined dimensions;

a first crankcase having first and second substantially symmetrical portions, said first crankcase having an opening therein communicating with said first cylinder;

a first piston adapted for reciprocal movement in said first cylinder;

a first crankshaft adapted for rotational movement within the first crankcase;

a first connecting rod having a length, L₁, said first connecting rod operatively connecting said first piston to said first crankshaft; and

,

a first camshaft operably associated with said first crankshaft and being operable to selectively operate a valve assembly, wherein said basic engine is associated with a first power output;

providing a second engine design for providing a second engine related to said basic engine, wherein at least one of said basic engine components is replaced with a corresponding modified engine component substantially different from said basic engine component, wherein said second engine is associated with a second power output being substantially different from said first power output;

selecting a cylinder block defining a cylinder of predetermined dimensions;

selecting a piston corresponding to said selected cylinder block;

selecting a connecting rod;

selecting a crankcase;

selecting a crankshaft; and

,

selecting a camshaft.

8. A method for manufacturing an engine having a predetermined power output utilizing an engine design system, wherein the engine design system provides engine components comprising a plurality of cylinder blocks, a plurality of pistons, a plurality of connecting rods, a plurality of crankcases, a plurality of crankshafts, and a plurality of camshafts, wherein a selection of engine components cooperate to provide said engine having said predetermined power output, the method comprising the steps of:

providing a first engine design for providing a basic engine associated with a first power output, said basic engine being formed of selectively replaceable basic engine components, wherein said basic engine components include;

a first cylinder block defining a first cylinder therein having first predetermined physical dimensions,

a first crankcase,

a first piston, said piston having first predetermined dimensions,

a first camshaft,

a first connecting rod having a length L₁,

a first crankshaft, said first crankshaft and said first connecting rod operably defining a first piston stroke;

providing a second engine design for providing a second engine related to said basic engine wherein said second engine is associated with a second power output, said second power output being substantially different than said first power output and wherein said second engine design utilizes;

said first cylinder block defining said first cylinder therein having said first predetermined physical dimensions,

said first crankcase,

said first piston,

said first camshaft,

a second connecting rod having a length L₂, wherein L₂ differs from L₁, said second connecting rod selectively replacing said first connecting rod, and

a second crankshaft, said second crankshaft selectively replacing said first crankshaft, said second crankshaft and said second connecting rod operably defining a second piston stroke substantially different from said first piston stroke;

providing a third engine design for providing a third engine related to said basic engine wherein said third engine is associated with a third power output, said third power output being substantially different from said first power output and said second power output, wherein said third engine design utilizes;

two of said first cylinder blocks each defining said first cylinder therein having said first predetermined physical dimensions,

two of said first pistons,

two of said first connecting rods wherein each first connecting rod is operably associated with a different one of said first pistons;

a modified crankcase, said modified crankcase selectively replacing said first crankcase, said modified crankcase having two openings therein, each of said openings communicating with a different one of said first cylinders;

a third crankshaft, said third crankshaft selectively replacing said first crankshaft, said third crankshaft and said first connecting rods operably defining third piston strokes for each of said first pistons of said third engine wherein said third piston strokes are substantially equal to said first piston stroke of said basic engine;

a modified camshaft being operable to selectively operate two of said valve assemblies, each of said valve assemblies being associated with a different one of said first cylinder blocks, said modified camshaft selectively replacing said first camshaft;

providing a fourth engine design for providing a fourth engine related to said basic engine wherein said fourth engine is associated with a fourth power output, said fourth power output being substantially different than said first power output and wherein said fourth engine design utilizes;

two of said first cylinder blocks each defining said first cylinder therein having said first predetermined physical dimensions,

two of said first pistons,

two of said second connecting rods wherein each second connecting rod is operably associated with a different one of said first pistons,

said modified crankcase, said modified crankcase selectively replacing said first crankcase, wherein each of said openings communicates with a different one of said first cylinders,

a fourth crankshaft, said fourth crankshaft selectively replacing said first crankshaft, said fourth crankshaft and said second connecting rods operably defining fourth piston strokes for each of said first pistons of said fourth engine wherein said fourth piston strokes are substantially equal to said second piston stroke of said second engine, and

said modified camshaft being operable to selectively operate two of said valve assemblies, each of said valve assemblies being associated with a different one of said first cylinder blocks, said modified camshaft selectively replacing said first camshaft;

selecting a cylinder block defining a cylinder of predetermined dimensions;

selecting a piston corresponding to said selected cylinder block;

selecting a connecting rod;

selecting a crankcase;

selecting a crankshaft; and

,

selecting a camshaft.