Novel Design of a Rotary Valve using Axiomatic Design by Robert (Beto) Bilgor Peliks S.B., Mechanical Engineering (2003) Massachusetts Institute of Technology Submitted to the Department of Mechanical Engineering in Partial Fulfillment of the Requirements for the Degree of Master of Science at the Massachusetts Institute of Technology June 2005 © 2005 Massachusetts Institute of Technology All rights reserved Signature of Author Department of Mechanical Engineering March 25, 2005 Certified by Nam Pyo Suh Ralph E. Cross Professor of Mechanical Engineering Thesis Supervisor Accepted by Lallit Anand Professor of Mechanical Engineering Chairman, Department Committee on Graduate Studies NOVEL DESIGN OF A ROTARY VALVE USING AXIOMATIC DESIGN by Robert (Beto) Bilgor Peliks Submitted to the Department of Mechanical Engineering on March 25, 2005 in partial fulfillment of the requirements for the Degree of Master of Science ABSTRACT Rotary valves have existed for millennia; and while they have developed tremendously since the first Roman valves, many of the same problems have persisted. The basic problems are caused by the coupling of functional requirements, which limits the valve’s performance. Using axiomatic design (AD), two of these couplings, including the coupling of the friction-sealing FRs, are studied and resolved. Although more work can be done to improve the patent-pending designs, the concepts presented represent advancements over existing rotary valve designs. The proposed designs have been analyzed for their merits as a valve and for their potential applications, such as in automotive engines. Thesis Supervisor: Nam Pyo Suh Title: Ralph E. Cross Professor of Mechanical Engineering 2 ACKNOWLEDGEMENTS 3 TABLE OF CONTENTS ACKNOWLEDGEMENTS..........................................................................................................................3 TABLE OF CONTENTS..............................................................................................................................4 1. INTRODUCTION ...............................................................................................................................6 2. INTERNAL COMBUSTION ENGINE...................................................................................................7 2.1. THE IC ENGINE.................................................................................................................................... 7 2.2. THE ECOGIN........................................................................................................................................ 7 3. ROTARY VALVE...................................................................................................................................11 3.1. PRIOR ART......................................................................................................................................... 11 3.1.1. Valves........................................................................................................................................ 11 3.1.2. Rotary Valves............................................................................................................................ 12 3.1.3. AD Applied to Rotary Valves .................................................................................................... 14 3.2. ROTARY VALVE REVOLUTION........................................................................................................... 23 3.2.1. THE MAIN IDEA ...................................................................................................................... 23 3.2.2. SOME VARIABLES................................................................................................................... 25 3.2.2.1. GEOMETRY ..................................................................................................................................... 25 3.2.2.2. ORIENTATION (GEOMETRIC / PRESSURE) ............................................................................... 26 3.2.2.3. MATERIALS..................................................................................................................................... 28 3.2.2.4. ACTUATION .................................................................................................................................... 28 3.2.2.5. OPENING .......................................................................................................................................... 29 3.2.3. THE SAMPLES ......................................................................................................................... 30 3.2.3.1. D01A.................................................................................................................................................. 30 3.2.3.2. D01B.................................................................................................................................................. 39 3.2.3.3. D02A.................................................................................................................................................. 46 3.2.3.4. D02B.................................................................................................................................................. 54 3.2.3.5. D03A.................................................................................................................................................. 59 3.2.3.6. D03B.................................................................................................................................................. 64 4. TECHNICAL...........................................................................................................................................69 4.1. WEAR ................................................................................................................................................ 69 4.2. CYCLIC FATIGUE................................................................................................................................71 4.3. DYNAMICS ......................................................................................................................................... 76 4.4. POWER ............................................................................................................................................... 79 4.4.1. Inertial Power ........................................................................................................................... 79 4.4.2. Drag Power............................................................................................................................... 80 4.4.3. Pressure Power......................................................................................................................... 81 4.4.4. Frictional Power....................................................................................................................... 81 4.4.5. Total Power............................................................................................................................... 82 4.5. FORCES.............................................................................................................................................. 83 5. EXPERIMENTAL (SEALING).............................................................................................................85 5.1. INTRODUCTION AND SETUP ................................................................................................................ 85 5.2. RESULTS............................................................................................................................................. 87 5.2.1. Large Port................................................................................................................................. 87 5.2.2. Meshed Port.............................................................................................................................. 88 5.3. SUMMARY...................................................................................................................................... 88 6. CONCLUSION........................................................................................................................................91 7. APPENDIX ..............................................................................................................................................93 4 7.1. PRESSURE TESTS—RAW DATA ........................................................................................................... 93 7.2. IMAGES.............................................................................................................................................. 94 8. ADDENDUM: THE FR-DP MAP..........................................................................................................97 8.1. ABSTRACT ......................................................................................................................................... 97 8.2. INTRODUCTION .................................................................................................................................. 97 8.3. PAST WORK....................................................................................................................................... 98 8.3.1. Design Matrix ........................................................................................................................... 98 8.3.2. Tree Diagram...........................................................................................................................