BLOCK MOUNTED OVERHEAD CAM SUPPORT SYSTEM FOR

INTERNAL COMBUSTION ENGINES

Cross-Reference to Related Application:

[0001] The present application claims the benefit of the filing date of US

Provisional Application Ser. No. 62,472/273 filed on March 16, 2017, which is incorporated herein by reference in its entirety.

Field of the Invention:

[0002] The present invention relates generally to internal combustion engines, and more particularly to systems, devices and methods for a modular overhead cam support system that is mounted to a cylinder block of the internal combustion engine independently of the cylinder head.

BACKGROUND

[0003] Large diesel and natural gas engines typically employ cam-in-block arrangements utilizing a push rod driven valve train. Cam-in-block designs can lead to a reduction in strength and stiffness in the cylinder block, additional mass, and service challenges. Cam-in-block designs also incur additional valve train inertia and other losses, and impose limitations on the block and cylinder head design.

[0004] By moving the camshaft out of the block and into an overhead position, various different valve train arrangements can be implemented. However, adding the camshaft above the cylinder head has led to restrictions in the serviceability of individual cylinders. Also, long multi-cylinder slab heads are not favorable due to their serviceability and manufacturing complexity. In addition, placing the valve Atty Docket No. CECO1512/16-0533-EBU

train on top of a slab cylinder head significantly increases the total assembly mass and complexity of the slab head system, negatively impacting the serviceability and repair time for the customer.

[0005] As desired cylinder operating pressures increase and more complex valve train arrangements are required for new engine designs, it would be desirable to have flexibility in the engine hardware to be integrated into those designs and be able to share common parts across engine families. Cam phasing, cam timing, cylinder deactivation, cam switching, cam duration, variable valve lift, and cam -less technology will become a significant enabler for engine manufacturers to allow additional optimization and improvement in engine efficiency and emissions reduction. Therefore, further improvements in this technology area are needed to address these issues, among others.

Atty Docket No. CECO1512/16-0533-EBU

SUMMARY

[0006] One embodiment of the present disclosure includes a unique system, method and/or apparatus for a modular overhead cam support system that can be apphed to inline and V-type internal combustion engines, where the cam support system is mounted to the engine independently of the cylinder head. The overhead cam support system can be configured for single, twin and other cam or cam -less configurations including cam-in-cam arrangements.

[0007] The overhead cam support system in the present disclosure enables the use of a shorter (l, 2, 3 or 4 cylinder) cylinder head while also providing the potential for various overhead valve train and camshaft configurations. The overhead cam support system also enables the use of variable valve actuation (WA) technology for complex markets including cam phasing of intake and exhaust events as well as variable valve lift and duration. The overhead cam support system can enable the engine architecture to be easily adapted to provide a de-tiered or simple overhead cam arrangement for cost-sensitive less regulated markets.

[0008] The overhead cam support system provides modularity and flexibility that enables tailoring of an engine family for different fuel variants while retaining the same base engine architecture and thus reducing the number of new, fuel specific components needed. The overhead cam support system allows for different heads to be interchanged independently of the overhead arrangement, allowing an increase in option flexibility, an increase in part commonality and a reduction in

development cost.

[0009] The overhead cam support system improves the serviceability of the cyhnder head assembly on large, multi -cylinder engines by enabhng the use of shorter cylinder heads that span fewer cylinders (l or 2 or 3 or 4 cylinders at a time).

Shorter cylinder heads reduce the mass of the serviceable item and help enable the Atty Docket No. CECO1512/16-0533-EBU

manual handling of the cylinder heads in the field. This is a significant advantage over longer, heavier slab cylinder heads, such as those used in space constrained environments such as marine, mining and mobile power generation engines due to the limited engine bay space. In addition, repair times are reduced and the modularity provides cost reduction due to the applicability of the overhead cam support system to multiple engine platforms.

[0010] The overhead cam support system is also scalable and can enable the use of two cam carrier housings per cylinder bank for dual overhead cam designs. This embodiment can utilize multiple sections of camshaft that are coupled together to span more than one cylinder head assembly. In certain embodiments, two sections of camshaft are used per cylinder bank, but the use of more than two cam sections per cylinder bank is also possible. The coupling between the camshafts can be configured so that one section of the cam carrier housing can be removed without requiring the removal of a neighboring section. The overhead cam support system also includes the option to retain the camshaft assembly and follower assembly to the cam carrier housing when removing for service and assembly. This helps to ensure cam timing and phasing is maintained during routine maintenance and enables the manufacturing facility to sub-assemble the system.

[0011] In further embodiments, the overhead cam support system can provide lash adjustment through the use of hydraulic tappets that reduce the need for routine lash maintenance. The overhead cam support system can also provide independent interchangeability of the head assembly to the valve train. Furthermore, the overhead cam support system allows the cylinder head to flex without transferring any loads into the valve train / camshaft assembly, such as may occur in response to intake manifold overpressure (IMOP) events, since the overhead cam support system is mounted to the engine block independently of the cylinder head. The Atty Docket No. CECO1512/16-0533-EBU

overhead cam support system also provides scalable overhead cam arrangements that work with multiple cylinder head engine arrangements.

[0012] This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.

Atty Docket No. CECO1512/16-0533-EBU

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The description herein makes reference to the accompanying drawings wherein like numerals refer to like parts throughout the several views, and wherein^

[0014] Fig. 1 is a cross -sectional view of a dual overhead cam support system mounted to the engine block.

[0015] Fig. 2 is a plan view of the dual overhead cam support system of Fig 1.

[0016] Fig. 3A-3D show various dual overhead cam support system arrangements and engine configurations.

[0017] Fig. 4 is a perspective view of another embodiment dual overhead cam support system which would be mounted to the engine block.

[0018] Fig. 5 is a perspective view of an engine block with an inboard exhaust system and a dual overhead cam support system mounted to the engine block.

[0019] Fig. 6 is an exploded perspective view of one embodiment of a coupling arrangement between camshaft sections.

[0020] Fig. 7 is a perspective view of a single two cylinder head of a V- 16 engine embodiment.

[0021] Fig. 8 is the engine of Fig. 7 with multiple two cylinder heads arranged on the cylinders of the engine block. Atty Docket No. CECO1512/16-0533-EBU

[0022] Fig. 9 is the engine of Fig. 7 with support legs of the dual overhead cam support system mounted to the engine block.

[0023] Fig. 10 is the engine of Fig. 9 with the cam carriers mounted to the support legs and drive couplings engaged to the cams.

[0024] Fig. 11 is an end view of the engine and cam support system of Fig. 10.

Atty Docket No. CECO1512/16-0533-EBU

DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

[0025] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will

nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated embodiments, and any further applications of the principles of the invention as illustrated therein as would normally occur to one skilled in the art to which the invention relates are contemplated herein.

[0026] Figs. 1 and 2 show a cross-section view and a plan view, respectively, of a modular dual overhead cam support system according to one embodiment of the present disclosure. It should be understood the cam support system disclosed herein can be employed on other overhead cam arrangements that are not dual overhead camshafts, as discussed above. Cam support system 10 is independently supported on the cylinder block 100 of the engine and not on or by the cylinder head 150. Cam support system 10 allows the cylinder head 150 to flex without

transferring any loads into the valve train / camshaft assembly supported by cam support system 10. Cam support system 10 provides scalable overhead cam support arrangements that work with multiple cylinder head types of engines.

[0027] Fig. 1 shows two overhead camshafts 12a, 12b that are each engaged with a respective one of the roller follower valve trains 14a, 14b with hydraulic lash adjusters 16a, 16b. Adjusters 16a, 16b can each include or be connected to an intake valve or an exhaust valve and an associated valve spring. Each intake or exhaust valve is connected to a hydraulic tappet that is connected with a respective roller follower that pivots around a follower pivot. The overhead cam support system 10 is mounted, independently of the cylinder head 150, directly to the engine Atty Docket No. CECO1512/16-0533-EBU

block 100 and sits above the cylinder head 150. A sealed interface between the head 150 and cam support system 10 is provided by seal 18 (such as an elastomer seal) which keeps oil inside the rocker housing and dirt out.

[0028] Cam support system 10 includes a carrier housing 20 to support camshafts 12a, 12b that in the illustrated embodiment of Figs. 1-2 is a single or unitary piece. Carrier housing 20 could also be arranged in two pieces to improve assembly and disassembly while in service. Carrier housing 20 includes a first leg 21a along one side of cylinder head 150 and a second leg 21b along a second, opposite side of cylinder head 150. A valve cover 22 can be engaged to the upper end of the cam carrier 29a, 29b of carrier housing 20 which is supported on the carrier legs 21a, 21b. Carrier bolts 24a, 24b can be provided that extend through bores in carrier housing 20 or alternatively through the carrier legs 21a, 21b to engage block 100. In the illustrated embodiment, carrier housing 20 includes a vertically extending wall portion 23a, 23b, 26a, 26b that includes a lower end sitting on block 100 and an opposite upper end engaged to valve cover 22. Each wall portion 23a, 23b, 26a, 26b includes inwardly extending flange 28a, 28b to provide engagement with seal 18 against head 150. Each wall portion 26 includes a cam support arm 29a, 29b that supports respectively one of the camshafts 12a, 12b thereon. A camshaft retaining cap 31a, 31b can be engaged to respective ones of support arm 29a, 29b around the correspondingly supported camshaft 12a, 12b. Carrier housing 20 may also include one or more support structures for rocker pivots, seals for cam-to-cam drive couplings, a cam/rocker cover, and suitable sealing arrangements to prevent the egress of fluids. Carrier housing 20 may also house hydraulic lash adjusters, tappets, and parts of the lubrication circuit for the cam, follower, and hydrauhc lash adjusters.

[0029] Fig. 2 shows a plan view of the overhead cam support system 10 in a V-8 configuration. Carrier housing 20 includes end walls 23a, 23b connecting legs 21a, Atty Docket No. CECO1512/16-0533-EBU

21b to provide a rectangular-shaped carrier housing. In another embodiment, the lower portions of the end walls 23a, 23b can be omitted so legs 21a, 21b are not directly connected to one another. A common cam drive gear 102 connected to the crank shaft is provided on carrier housing 20 in the center between camshafts 12a, 12b and two cam gears 104a, 104b, One drive gear 102 and cam gears 104a, 104b can be provided for each of the left cylinder bank and the right cylinder bank. For variable valve timing (WT) or WA arrangements, the cam gears 104a, 104b can be interchanged for cam phasers. It is further contemplated that an electric drive, chain, or belt can drive the camshafts 12a, 12b.

[0030] Figs. 3A-3D show the principle of using multiples of a two cylinder head 150 to cover pairs of engine cylinders including a V-8 in Fig. 3A, a V- 16 in Fig. 3B, a V- 12 in Fig. 3C, and a V-20 in Fig. 3D. Other engine sizes and cylinder numbers are also contemplated other than those shown. Also shown are cam support systems 10 that span heads that cover two cylinder pairs such as shown in Fig. 3A, and also a cam support system 10' sized to span three cylinder pairs as shown in Fig. 3C, a cam support system 10" sized to extend over four cylinder pairs as shown in Fig. 3B. Combinations of these are also contemplated as shown in Fig. 3D. Figs. 3B and 3D also show couplings 30a, 30b (also collectively or individually referred to as coupling 30) to connect two sections of respective ones of the camshafts 12a, 12b together. In one embodiment of the V- 12 engine shown in Fig. 3C, a first camshaft section can be provided that is sized to extend along two cylinder pairs and a second camshaft section is provided to extend along one cylinder pair on each side of the cylinder bank, and the first camshaft section is connected in end-to-end fashion with the second camshaft section. In still another embodiment, a unit head engine is provided with a single head per cylinder. For a V- 12 engine, each of the camshaft sections can be connected in end-to-end fashion and are each sized to extend along three cylinders. Atty Docket No. CECO1512/16-0533-EBU

[0031] Fig. 4 shows one bank of another embodiment overhead cam support system 200 for a V-8 configuration engine with double overhead valvetrain. Cam support system 200 incorporates a single piece cam carrier housing 202 with mounting legs 204 that extend downwardly from the center wall section 203 of housing 202 for engagement with the engine block 100. Each of the legs 204 includes a bore to receive an elongated bolt or other fastener for connection of carrier housing 202 to the engine block. The central drive gear 102 is mounted to the carrier housing 202 to allow the assembly to be removed in one piece and with the timing locked in place. Carrier housing 202 also includes cam support arms 206 that extend upwardly from center wall section 203 and inwardly toward one another to support camshafts 12a, 12b relative to the cylinder heads.

[0032] Fig. 5 shows one embodiment of an inboard exhaust system 300 using multiple sections 302a, 302b that could be joined together with a flexible connection, such as a bellows or sliding piston type joint. Each section 302a, 302b sits on a common mounting face of a respective cylinder head 150 to help to reduce assembly variation and tolerance stack up. The exhaust system 300 arranged in this example can use a log manifold, and the extra material in the cylinder head 150 for

supporting the respective exhaust manifold section can also include internally a pulse converter to reduce the effect of cylinder back filling, thus improving engine scavaging capability and reducing in-cylinder residuals.

[0033] Fig. 6 shows one embodiment of a camshaft coupling 30. The camshaft coupling 30 can connect two camshaft sections 32, 34 to one another in end-to-end fashion. In one embodiment, coupling 30 includes a center hub 36 with splined sections 38, 40 extending axially in opposite directions from center hub 36. In addition, each splined section includes a key 42, 44 projecting radially outwardly therefrom. Camshaft sections 32, 34 each include a longitudinal bore 46, 48 with a corresponding keyway that receives respective ones of the splined sections 38, 40 Atty Docket No. CECO1512/16-0533-EBU

and its associated key 42, 44 in the key way. In certain embodiments, sp lined sections 38, 40 include other configurations, such as a D-shaped or other shape that is received in a correspondingly complementary non-circular shaped longitudinal bore 46, 48. The camshaft coupling 30 can be used to connect camshaft sections in engines that, for example, have more than 8 cylinders.

[0034] Figs. 7- 11 show another embodiment overhead cam support system 400 in which the carrier housing is comprised of multiple sections. In Fig. 7 an engine block 100 is shown with sixteen cylinders 116 and one pair of the cylinders 116a of a first cylinder bank is covered by a first cyhnder head 150. Fig. 8 shows the same block 100 with cylinders 116a in the first cylinder bank and cylinders 116b in a second cyhnder bank, and with eight cylinder heads 150a, 150b over respective pairs of the cylinders 116a, 116b.

[0035] In Fig, 9 cam support system 400 includes a lower carrier housing section 402a with legs 408a, 409a (see also Fig. l l) along the opposite sides of cylinder heads 150a and the valve train of the first cyhnder bank, and a second lower carrier housing section 402b with legs 408b, 409b along the opposite sides of cylinder heads 150b and the valve train of the second cyhnder bank. Legs 408a, 409a and legs 408b, 409b are provided at each end of each cylinder head 150a, 150b and between adjacent ones of the cyhnder heads 150a, 150b. The legs 408a, 409a, 408b, 409b on each side of the cyhnder heads 150a, 150b are connected by a flange 410, and a plurality of bores are provided in legs 408a, 408b, 409a, 409b and flanges 410 to receive bolts to secure the lower section to block 100.

[0036] Figs. 10 and 11 show the overhead cam support system 400 with upper sections 404a, 404b mounted the respective lower sections 402a, 402b. In the illustrated embodiment, each upper section 404a, 404b includes two parts that each span two cyhnder pairs 150a, 150b. The upper sections 404a, 404b each have a Atty Docket No. CECO1512/16-0533-EBU

rectangular shape with opposite sidewalls and endwalls connecting the opposite sidewalls, and the idler gear 102 connected to one of the endwalls of each upper section 404a, 404b. This embodiment reduces machining complexity of the cam support system 400, and improves serviceability, especially in applications where the front or rear of the engine is constrained and access restricted.

[0037] Various aspects of the present disclosure are contemplated. According to one aspect, an overhead cam support system includes a carrier housing with a lower end positionable on an engine block independently of a cylinder head of the engine. The carrier housing rotatably supports at least one camshaft on the engine block for engagement with at least one valve of the cylinder head.

[0038] In one embodiment, the system includes a valve cover engaged to an upper end of the carrier housing that is opposite the lower end of the carrier housing. In one refinement of this embodiment, the carrier housing includes a flange extending over an upper surface of the cylinder head, and a seal is provided between the flange and an upper surface of the cylinder head. In another refinement, the carrier housing includes at least one cam support arm extending outwardly therefrom adjacent the upper end of the carrier housing, and the camshaft is supported on the at least one cam support arm. In a further refinement, the system includes a camshaft retaining cap engaged to the cam support arm and the camshaft retaining cap extends around the at least one camshaft.

[0039] In another embodiment, the at least one camshaft includes first and second camshafts including respective ones of first and second cam gears or phasers that are engaged to an idler gear mounted to the carrier housing. In yet another embodiment, the carrier housing includes first legs and second legs extending on opposite sides of the cylinder head and a first flange and a second flange extending along opposite sides of the cylinder head connecting the first legs and the second Atty Docket No. CECO1512/16-0533-EBU

legs, respectively. In still another embodiment, the engine block includes at least eight cylinders and each cylinder head extends over two cylinders.

[0040] In another embodiment the at least one camshaft includes at least two camshaft sections connected to one another in an end-to-end manner. In a refinement of this embodiment, the system includes a camshaft coupling that includes a center hub with splined sections extending axially in opposite directions from the center hub, and each camshaft section includes a longitudinal bore configured to receive respective ones of the splined sections. In a further

refinement, each splined section includes a key projecting radially outwardly therefrom that is received in a keyway along the longitudinal bore of the respective cam section. In another further refinement, each splined section includes a non- circular cross-section that is received in a complementary shaped one of the longitudinal bores.

[0041] In yet another refinement, a first camshaft section is sized to extend along three cylinder pairs and a second camshaft section is sized to extend along two cylinder pairs, and the first and second camshaft sections are connected in end-to- end relation. In still another refinement, a first camshaft section is sized to extend along two cylinder pairs and a second camshaft section is sized to extend along two cylinder pairs, and the first and second camshaft sections are connected in end-to- end relation. In another embodiment, a first camshaft section is sized to extend along two cylinder pairs and a second camshaft section is sized to extend along one cylinder pair, and the first and second camshaft sections are connected in end-to- end relation. In yet another embodiment, a first camshaft section is sized to extend along three cylinders and a second camshaft section is sized to extend along three cylinders, and the first and second camshaft sections are connected in end-to-end relation. Atty Docket No. CECO1512/16-0533-EBU

[0042] In another embodiment, the carrier housing includes a plurality of bores for receiving fasteners to secure the carrier housing to the engine block. In yet another embodiment, the engine block is configured for an in-line engine cylinder

arrangement. In one refinement, the number of cylinders is at least six.

[0043] In another embodiment, the engine block is configured for a V-shaped engine cylinder arrangement. In yet another embodiment, the camshaft is a single piece, single overhead camshaft. In a further embodiment, the camshaft includes at least two camshafts positioned in a double overhead arrangement and each of the at least two camshafts is a single piece camshaft. In still another embodiment, the system is a cam -less valve train.

[0044] According to another aspect of the present disclosure, an overhead cam support system includes a carrier housing configured to extend around a cylinder head of an engine. The carrier housing includes a lower end supported on an engine block of the engine independently of the cylinder head. The carrier housing includes at least one cam support arm extending over the cylinder head that rotatably supports at least one camshaft on the engine block.

[0045] In one embodiment, the system includes a camshaft retaining cap engaged to the cam support arm and the camshaft retaining cap extends around the at least one camshaft. In another embodiment, the carrier housing includes a plurality of first legs and a plurality of second legs on opposite sides of the cylinder head. The plurality of first and second legs each define a bore for receiving a fastener to secure the carrier housing to the engine block. In yet another embodiment, the carrier housing includes a flange extending over an upper surface of the cylinder head, and a seal is provided between the flange and an upper surface of the cylinder head. Atty Docket No. CECO1512/16-0533-EBU

[0046] In another aspect of the present disclosure, an overhead cam support system includes a lower carrier housing section and an upper carrier housing section mounted on the lower carrier housing section. The lower carrier housing section includes a plurality of legs with lower ends supported on an engine block along opposite sides of a cylinder head of an engine independently of the cylinder head. The lower carrier housing further includes flanges extending between and

connecting adjacent pairs of the plurality of legs. The upper carrier housing section includes opposite sidewalls and opposite endwalls connecting the opposite sidewalls. The opposite endwalls are configured to rotatably support at least one camshaft along the cylinder head.

[0047] In one embodiment, at least a portion of the plurality of legs include a bore for receiving a fastener to secure the lower carrier housing section to the engine block. In another embodiment, the upper carrier housing section includes at least one cam support arm extending from one of the opposite sidewalls over the cylinder head and the camshaft is supported on the at least one cam support arm.

[0048] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain exemplary embodiments have been shown and described and that all changes and

modifications that come within the spirit of the inventions are desired to be protected. In reading the claims, it is intended that when words such as "a," "an," "at least one," or "at least one portion" are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language "at least a portion" and/or "a portion" is used the item can include a portion and/or the entire item unless specifically stated to the contrary.