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A New Class of Rotary Piston Machine Suitable For Compressors Pumps and Internal Combustion Engines
A New Class of Rotary Piston Machine Suitable For Compressors Pumps and Internal Combustion Engines
P. H. Hamilton*
The mechanisms and porting requirements of a new class of rotary piston machine are described. The
machines can be regarded as a generalization to three dimensions of that class of planetary motion machine
which includes the Wankel. Important features of the Wankel engine are retained, namely a compact arrangement, a sliding contact seal grid and multiple chambers on each rotor, but these new machines have twice as
many chambers on each rotor, and they apply results of three-dimensional rigid body dynamics to select piston
motions which involve very low inertial forces. An experimental engine is described with some results.
1 INTRODUCTION
PATENT
LITERATURE contains hundreds of devices of great
ingenuity which stem from a desire to avoid the reciprocating piston and yet connect chambers of varying volume
with a rotating shaft. Only the Wankel engine has achieved
any great commercial interest.
The machines outlined in this paper form a new group
also based on compound rotation, i.e. rotation about a
moving axis. But while the rotor axis of the Wankel
engine sweeps a circular cylindrical surface the rotor axis
in these machines sweeps a circular conical surface so that
its centre of gravity, at the apex of the cone, does not move.
These machines are not featured in surveys (1)-(3)t
of rotary piston machines although Dr Felix Wankel was
clearly aware (I) (4) that there were possibilities in this
direction. The machines are free from vane or flap type
components and they retain the very important internalaxis feature which allows the adoption of a sliding continuous contact seal arrangement so that use as an engine
is practicable as in the case of the Wankel engine and the
Hamilton-Walker engine (5)$. In the latter the seal line is
also a mechanical constraint on the motion of the piston.
External axis machines such as the helical screw compressor (a), the Dean gear engine (7) and the Marshall
tri-dyne engine (8) suffer from their inherent inability to
use contacting seals. Other important features of the
Wankel such as the elegant use of ports to avoid valve
mechanisms and the compact arrangement are shared by
this new group.
It is demonstrated in Appendix 1 that the dynamics of
the rotors in these machines are favourable. In some of
them the inertial forces applied to the bearings are so small
This paper is intended for presentation at an Ordinary Meeting on
18th October 1972. The M S . was received on 8th May 1972 and
accepted for publication on 21st July 1972. 22
* Turbo Machinery Department, National Gas Turbine Establishment, Pyestock, Farnborough, Hants.
References are given in Appendix 2.
$ No connection with the authors.
inertia.
Effective area for leakage through seal gaps
and clearances.
Constant having dimensions of angular momentum.
Couple magnitude.
Functions of and /3.
Function of Ap/p.
Shaft moments of inertia about axes of rotation.
Mass of rotor.
Principal rotor moments of inertia.
Initial fluid mass in chamber.
Mass of fluid leaked through seals.
Defined by equation (15), for a machine with
fixed ports it is an integer greater than 1
and equals the number of chambers on
each side of a rotor.
Fraction of cycle period for which outflow
can occur from chamber.
Pressure in a chamber.
Vol 186 62/72
744
AP
R
T
t
V
vc
B
R
P
Pc
7
2 MECHANISMS
-Rotor
Rotor
Bevel shaft
\
Slidi
-.
,-
Layshaft-
Bevel shaft\
n-/
I
I
Rotor
Mainshaft
i
I
I
I
!
.
\
Layshaft
ku
Contact
- -face
. F
Rotor
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
745
It is shown in Appendix 1 that each of the above mechanisms constrains the rotor to move in a manner which
satisfies the condition for making a positive displacement
device with ports in a static casing. The shape of the casing
is defined by fixing a seal line in the rotor and then moving
the mechanism. As the rotor moves this line sweeps a
surface which is continuous. In the case of the Wankel
engine the casing surface is an epitrochoidal cylinder. The
remainder of the rotor outline can then be defined as the
largest rigid object which does not touch this surface.
Figs 4 and 5 show computer generated pictures of precessing rotors moving relative to fixed static surfaces
3 SEAL SURFACE S H A P E S
746
4 PORTING
120
240
360SHAFT480
600
120
60
120
180
ROTOR
240
300
360
__
.--..
Volume
,pK-\.
Inlet area -/ Outlet area
4
/!-\
_ c -
\<,
->A
0
F i g . 7. Four-cycle engine
Proc lnstn Mech Engrs 1972
_c
60
120
\/f\h*.
I80
ROTOR
240
300.
360
Fig. 9. Compressor
Vol 186 62/72
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
747
which A p is significantly positive and assuming A , is constant during the cycle gives
5 THRUST L O A D S A N D B A L A N C I N G
niL=ALdGfe)
. . .
m, = p , V c
.
. . (3)
where rn, is the trapped mass; V , is the initial chamber
volume and p , is an appropriate initial charge density.
The 5 per cent leakage criterion may be written
rn, > 20m,
. . . . (4)
and using equations (2) and (3) this can be expressed in the
form
p =-
RT
and f = 0.6847
V,
&
. .
(:)
20~0.6847J p
dRp,
oTTd-
(6)
(7)
and f =
iy
. .
N
4 so
(8)
that
748
Table 1
~
cycle
~~
i
Two-cycle engine
Precessing
Mechanism
Hookes
coupling
Sili
N.G.T.E.
Four-cycle engine
Not
Not
suitable
suitable
N.E.L.
expander
7 A TWO-CYCLE EXPERIMENTAL U N I T
By combining different porting arrangements with different mechanisms many different machines can be constructed. The possibilities are conveniently identified in
Table 1.
The National Engineering Laboratory is examining a
Lay shaft
Ports
Fig. 10. Longitudinal section through t h e experimental two-cycle engine
Vol I 86 62/72
749
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
.Apex real
pox seal -/
Fig. 12. Seal configuration
that this particular rig did not exploit the potential for
high speed operation and, at the same time, it made heavy
demands on the standard of sealing required.
7.1 Seals
asing
osing
Apex seal
Apex seal
Rotor
Principal
leakage
areas
surface contact. Also, like the Wankel the seal grid contains four corners. The tip seal is semicircular like half
a piston ring in the rotor. The circular hub seal is located
in the casing, and seals by inward acting forces as it slides
against the rotor hub sphere. The apex seals are located
by grooves in the rotor and slide on the casings. All the
seals are spring-loaded to ensure correct seating for starting but are mainly loaded by gas pressure in the conventional manner. The tip seal has not changed much during
development and has been made from a piston ring grade
of cast iron. Hub seals were originally cast iron but more
recently have been made in En 31 steel. Apex seals have
been tried in several materials including carbon and cast
iron.
Fig. 13 is a section through the apex seal of the first
design. Radial support of the apex seal is on the rotor.
The components are drawn in the extreme positions they
may occupy during operation. This movement between
extremes can arise from a combination of bearing clearances, different thermal expansions, load deflections,
surface form and position errors and timing gear backlash.
I n the first design, Fig. 13a, when the gas pressure forces
the rotor away from its casing leakage areas of up to 6 mm2
can be opened up at each apex seal.
The third design is shown in a similar fashion in Fig. 14.
The apex seal is now supported radially by sliding contact
on the casing and is made smaller and lighter. This simplifies the corner problems between the tip and apex seals.
The hub ring secondary sealing surface has been moved
out of the locating groove so that the latter no longer provides a circumferential leakage path. The part of the hub
ring on the expansion side of the engine has been provided
with an integral water-cooling passage and its expansion
gap has been sealed with a stepped design. The threepiece design of apex seal can accommodate changes of
seal-line length by relative motion of its members. The
maximum area exposed by clearance allowances is now
0.5 mm2 and at the most important period when gas
pressure forces the rotor away from the casings the corner
leakage disappears. Many other detail differences not
apparent in the diagrams have been introduced. I n particular the surface finish and form have been much
improved by lapping. All surfaces are either flat or spherical so that they lend themselves to this kind of precision
finishing operation.
Vol 186 62/72
150
0
First design
before modifications
First design
after rnodificotions
after
First design
rnodificotions
Second design
Identified
PI
de/ -
Third design
631compratio
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
75 1
(6) In the four cycle engines there is another considerable difference in the combustion chamber airflow near
t.d.c. Fig. 17 shows successive combustion chamber
shapes for both engines from which it can be seen that
the rapid transfer of gas across the waisted portion of the
Wankel engine chamber is absent from the precessing
version and so is the persistence near the trailing apex seal
of a pocket of gas which is remote from the combustion
process until late in the cycle. These differences may help
reduce heat loss and exhaust emissions when compared
with the Wankel engine.
(7) In the two-cycle casing machines the surfaces can
be made without special generating or cam-following
machinery and where flat and spherical surfaces are used
a high degree of precision and good finish is obtainable by
lapping.
9 CONCLUSION
a Precessing rotor.
b Wankel.
Fig. 17. Comparison of combustion chamber shapes
Proc lnstn Mech Engrs 1972
752
APPENDIX 1
I N E R T I A L FORCES FOR C O N S T R A I N E D P R E C E S S I O N ,
HOOKE'S C O U P L I N G M O T I O N A N D THE
WANKEL ENGINE
m1-m2
. .
(10)
11111712
tj
=a
1 cos2 $
(-----)
m,
m3
+-
sin2 J,
cos 8
m2
$1
. (11)
(cos2 J, sin2
a . . ,
m,
m2
The principal moments of inertia are m,, m2 and m3 and
m3 corresponds to the polar ($) axis and m2 to the 6' axis
when J, is zero. The multiplier, a, is a constant of the
motion having dimensions of angular momentum. Simple
rotation is the case when 6' = 0 because then
0 and $+$ = p / m , . . (13)
Steady precession occurs when m, = m2 because then
=
e=
e=O
and
c:
$ =cos6' --1
. (14)
-C
- N s i n O(l-N(l-cos
O(1-2)))
(18)
m,Q2
where Q is the apparent rotor rotation rate defined by
Q = d+$ and 6' is the fixed tilt angle of the shaft. This
formula holds for non-integer values of N although only
integer values from 2 upwards permit positive displacement machines in stationary casings.
Fig. 19 shows contours of constant couple covering the
range of positive N values from simple rotation ( N = 0)
through the swash plate ( N = 1) to the wobble plate
( N = a).
$ = .Q(F{#J})-'" . . . (19)
where 0 is a constant and F ( 4 ) is a known function of 4.
The Langrangian equations of motion can then be used to
give the couples C, and C, conjugate to the Eulerian
angles 6' and 4. They are
. . . (20)
<
. . .
- 112
1-sin2gsin2
4)
(16)
(17)
PRECESSION
RATE^+^-,
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
I
and
c*
2 tan /3 cos
1+tan2 ,6 cos2
G
F
w = -
m3Q2
153
l + B tan2 /3 cos2
d+ 2F2(1 tan2 /3 cos2 +) (21)
dF
--
CA = C,+Co sin
(22)
(23)
F=
+
+
60
90
120
SHAFT ANGLE $
shaft speed
p = 200
150
180
(27)
30
ICl = 0.1682MV2
0
-Constant
-0.06
(29)
(I) WANKEL,
F. Rotary piston machines 1965 (Iliffe Books Ltd,
London).
(2) SISTO, F. Comparison of some rotary piston engines,
770B, SAE National Powerplant Meeting, October 1963.
(3) CHINITZ,W. Rotary engines, Scienr. Am., February
1969.
(4) WANKEL,F. A slant-shaft rotary piston engine, U.K.
Patent Specification No. 805370, December 1954.
(5) The Walker rotary, Motor, February 1969.
(6) WICHERT,
K. W. Characteristics of helical, rotary, positive
displacement compressors, A.S.M.E. 61-MYD-18, May
1961.
(7) DEAN,W. C. A new rotary piston engine, Mech. Engng,
October 1964.
(8) Marshall tri-dyne rotary engine, The Engineer, March 1968.
(9) WHITTAKER,
E. T. AnaZytica2 dynamics 1944 (Dover Publications Inc., New York).
(10) THOMSON,W. T. Introduction to space dynamics 1961
(John Wiley and Sons, New York and London).
D261
Discussion
A. J. S. Baker Member
I should like to make a few comments regarding the
mechanical specifics of this very unusual class of machine.
Like the Wankel epitrochoid machine, the torque is not
transferred between the rotor and crank via the gearing.
However, the gearing plays an important part in keeping
the rotor accurately phased; in doing so it is subject to
significantloadings due to inertial forces induced by torque
fluctuations. These forces are usually of short duration and
reverse during the cycle. It is difficult to compute the
precise value of the gear loadings instantaneously as they
are influenced by several dynamic components. T o contain this, the gearing may need to be more generously
designed than would at first be supposed if scuffing and
other difficulties are to be avoided. The drive requirements
are somewhat similar to the zero power requirements of
dynamic balancers used in reciprocating engines, which,
in fact, sometimes need a drive capacity close to the average
engine torque.
The Clarke engine offers better scope for combustion
chamber design than some other rotary machines, since
it does not suffer from parasitic volumes at minimum
combustion volume. However, in the current examples
on show, it would appear that cooling around the chamber
may be inhibited by the thinness of the rotor section.
Could the authors state whether there is any geometric
objection to making the basic rotor rather thicker at the
section occupied by the chamber ?
Examination of the crank-displacement diagram shows
this to be sinusoidal. However, first approximation calculations suggest that this is not quite so. Could the authors
define the divergence ?
The machines promise exceptionally high volumetric
efficiency since the flow through them is pulsatory but
virtually continuous. In these circumstances, unit heat
fluxes for given gas conditions should be relatively low
owing to the absence of turbulence. Many data are now
available on the heat fluxes at the sort of fluid pressures
and temperatures to be expected for the Clarke-HamiltonWalker engine. Had the authors considered any comparisons with the relatively large swept areas of their
machines ? Some data from current Wankel epitrochoid
machines suggest that they at least may be somewhat
critical in this direction.
It would appear that the length of seals subject to
lubrication by constant loss methods is somewhat higher
than that of the Wankel and significantly more than an
engine with reciprocating pistons. In the prototype engine
it appeared that the opportunity to make the circumferential end seals recirculate oil had been avoided. Could
the authors give their comments on this point which
appears of importance to pollution and chamber fouling ?
Proc lnstn Mech Engrs 1972
S. A. Egberongbe Guildford
Rotary piston machines are not a novelty, but because of
Vol 186 62/72
D262
4 Chamber N.G.T.E.
P==f+E
2 Rotor 2 htre Wankel
4 Cylinder 2 litre reciprocating
2850
32
2200
85
54
m*
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
TRAILING
D263
LEAD1N G
-.
,TRAIL
4
I2
10
.
78
E
E
LL
0
0
2000
3000
4000
ROTATION SPEED rev/min
rn
Ir1 J- IJ
I,
-N.G.T.E.
engine.
4-cylinder reciprocating engine.
- - - - 2-rotor Wankel engine.
D264
E. Markland Member
Anyone interested in this class of machine as an engine
will naturally ask what was the net power output and fuel
consumption of the experimental unit. Neither of these is
given in the paper. The value quoted for measured brake
power, 18-1 kW, is quite meaningless-even misleadingin the absence of the corresponding figure for input
power to the supercharger which is necessary to run the
engine. Will the authors please give us their estimate of
this, on the basis of air consumption and supercharge
pressure used? May we also have the figure for fuel
consumption ?
The authors diagnosed the early failure of the engine as
a mixture of poor combustion and poor sealing and have
pursued the latter with apparent disregard of the former.
However, they now assert that combustion is satisfactory.
How can this be reconciled with the statement made, on
presentation of the paper, that large quantities of unburnt
fuel are discharged in the exhaust ?
Pressure ratio = 3: 1
Volumetric&deaCy
Tipspe.d(ms-)
Dynarmchead loss
Useful
head
__
0.8
40
0.1
0-9
80
0-25
Siugle rotor
Hookes coupling
Modified
Hookes coupling
Fig. 24
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
D265
4-cJrde
Reciprocptins
PB-t
0.164 m3
Minimum possible
clearance
volume
Am*.
Vmm
I 0
I oLessthan
-Wm3I
82-33m-
70.0 m-l
34-5
D266
Fig. 25
where cold backlash was too small there were no mechanical troubles attributable to the gears. All gears incidentally
were milled. The rotor can be made thicker at the design
stage simply by siting the seals further from the centre
plane of the rotor. In the case of designs having all the
seals in the rotor, the combustion chamber can be situated
partly in the hub sphere of the rotor. I n this way low
compression ratios could be accommodated without using
thicker rotors. Our calculations have shown volume
variations to be sinusoidal to within f0.06 per cent of the
sine semi-amplitude. We cannot agree entirely with the
suggestion that the turbulence may be low in the incoming air since the individual chambers will see a cyclic
variation in mass flow similar to that in the conventional
engine. Air motions within the chambers must affect heat
fluxes and probably differ between engines much more
significantly than the surface areas. It seems certain that
in this slant axis engine as in the parallel axis engine heat
losses are higher than those of the reciprocating engine
but the effect on fuel consumption may be partly offset by
lower friction. The hub rings have in fact been designed
to recirculate oil using the oil scraper and tapered land
technique but a poor surface finish of both hub and grooves
did lead to excessive oil passing this arrangement.
Pressures were in fact measured between the end seals.
Any detectable rise (3 kN/m2) presaged failure of the hub
compression ring. The capstan effect is relevant to the hub
and tip seals and the proper positioning of their anchor
points relative to the rotation direction. In fact the hub
ring was anchoredso that three-quarters ofthe circumference
wrapped on while a quarter wrapped off. The tip seals
were located so that their half-circumference lengths
wrapped off. This latter choice was based on discussion
Vol 186 62/72
ROTARY PISTON MACHINE SUITABLE FOR COMPRESSORS, PUMPS AND I.C. ENGINES
D267
Table 5
Compactness
No valves
I - 1 4 4
forces
Potentially high
compression ratio
-4
J I
-J-J
J
(12)MILLINGTON,
B. W. and HARTLES,
E. R.
Frictional losses in
diesel engines, S.A.E. Paper No. 680590, September 1968.