Crank mechanism with a high mechanical efficiency

This document describes the possibilities of increasing the mechanical efficiency of the crank train of an internal-combustion engine. For this purpose, a concept with a reduced number of main bearings is chosen and its contribution is verified experimentally. The proposed solution consists of an innovative crankshaft design of a four-cylinder spark-ignition engine with only three main journal bearings and laser-welded sheet metal crank webs. The new design is compared to the mass-produced one in terms of friction losses, vibrations and loading of engine parts by means of simulations of crank train dynamics using the Multi-Body System. The increase in vibration, accompanied by a reduction in friction losses, is compensated by a torsional vibration damper and its effect is experimentally verified. Experimental research of laser welds on the crankshaft in terms of fatigue life is also described. The overall potential is also summarised and further possible development of this innovative and patented design is outlined