Aviation Engines: Design—Construction—Operation and Repair

Some interesting details of the 160 horse-power Benz motor, which is shown at Fig. 246, are reproduced from the “Aerial Age Weekly,” and show how carefully the design has been considered.

• Maximum horse-power, 167.5 B. H. P.
• Speed at maximum horse-power, 1,500 R. P. M.
• Piston speed at maximum horse-power, 1,770 ft. per minute.
• Normal horse-power, 160 B. H. P.
• Speed at normal horse-power, 1,400 R. P. M.
• Piston speed at normal horse-power, 1,656 ft. per minute.
• Brake mean pressure at maximum horse-power, 101.2 pound per square inch.
• Brake mean pressure at normal horse-power, 103.4 pound per square inch.
• Specific power cubic inch swept volume per B. H. P., 5.46 cubic inch; 160 B. H. P.
• Weight of piston, complete with gudgeon pin, rings, etc., 5.0 pound.
• Weight of connecting rod, complete with bearings, 4.99 pound; 1.8 pound reciprocating.
• Weight of reciprocating parts per cylinder, 6.8 pound.
• Weight of reciprocating parts per square inch of piston area, 0.33 pound.
• Outside diameter of inlet valve, 68 mm.; 2.68 inches.
• Diameter of inlet valve port (d), 61.5 mm.; 2.42 inches.
• Maximum lift of inlet valve (h), 11 mm.; 0.443 inch.
• Area of inlet valve opening (π d h), 21.25 square cm.; 3.29 square inches.
• Inlet valve opens, degrees on crank, top dead center.
• Inlet valve closes, degrees on crank, 60° late; 35 mm. late.
• Outside diameter of exhaust valve, 68 mm.; 2.68 inches.
• Diameter of exhaust valve port (d), 61.5 mm.; 2.42 inches.
• Maximum lift of exhaust valve (h) 11 mm.; 0.433 inch.
• Area of exhaust valve opening (π d h), 21.25 square cm.; 3.29 square inches.
• Exhaust valve opens, degrees on crank, 60° early; 35 mm. early.
• Exhaust valve closes, degrees on crank, 16¹⁄₂° late; 5 mm. late.
• Length of connecting rod between centers, 314 mm.; 12.36 inches.
• Ratio connecting rod to crank throw, 3.49:1.
• Diameter of crank-shaft, 55 mm. outside, 2.165 inches; 28 mm. inside, 1.102 inches.
• Diameter of crank-pin, 55 mm. outside, 2.165 inches; 28 mm. inside, 1.102 inches.
• Diameter of gudgeon pin, 30 mm. outside, 1.181 inches; 19 mm. inside, 0.708 inch.
• Diameter of cam-shaft, 26 mm. outside, 1.023 inches; 18 mm. inside, 0.708 inch.
• Number of crank-shaft bearings, 7.
• Projected area of crank-pin bearings, 36.85 square cm.; 5.72 square inches.
• Projected area of gudgeon pin bearings, 22.20 square cm.; 3.44 square inches.
• Firing sequence, 1, 5, 3, 6, 2, 4.
• Type of magnetos, ZH6 Bosch.
• Direction of rotation of magneto from driving end, one clock, one anti-clock.
• Magneto timing, full advance, 30° early (16 mm. early).
• Type of carburetors (2) Benz design.
• Fuel consumption per hour, normal horse-power, 0.57 pint.
• Normal speed of propeller, engine speed, 1,400 R. P. M.

AUSTRO-DAIMLER ENGINE

One of the first very successful European flying engines which was developed in Europe is the Austro-Daimler, which is shown in end section in a preceding chapter. The first of these motors had four-cylinders, 120 by 140 millimeters, bore and stroke, with cast iron cylinders, overhead valves operated by means of a single rocker arm, controlled by two cams and the valves were closed by a single leaf spring which oscillates with the rocker arm. The cylinders are cast singly and have either copper or steel jackets applied to them. The four-cylinder design was afterwards expanded to the six-cylinder design and still later a six-cylinder motor of 130 by 175 millimeters was developed. This motor uses an offset crank-shaft, as does the Benz motor, and the effect of offset has been discussed earlier on in this treatise. The Benz motor also uses an offset cam-shaft which improves the valve operation and changes the valve lift diagram. The lubrication also is different than any other aviation motor, since individual high pressure metering pumps are used to deliver fresh oil only to the bearings and cylinders, as was the custom in automobile practice some ten years ago.

SUNBEAM AVIATION ENGINES

The modern Sunbeam engines operate with a mean effective pressure of 135 pounds with a compression ratio of 6 to 1 sea level. The connecting rods are of the articulated type as in the Renault motor and are very short. The weight of these motors turns out at 2.6 pounds per brake horse-power, and they are able to go through a 100 hour test without any trouble of any kind. The lubricating system comprises a dry base and oil pump for drawing the oil off from the base, whence it is delivered to the filter and cooling system. It then is pumped by a separate high pressure gear pump through the entire motor. In these larger European motors, castor-oil is used largely for lubrication. It is said that without the use of castor-oil it is impossible to hold full power for five hours. Coatalen favors aluminum cylinders rather than cast iron. The series of views in Figs. 247 to 250 inclusive, illustrates the vertical, narrow type of engine; the V-form; and the broad arrow type wherein three rows, each of six-cylinders, are set on a common crank-case. In this water-cooled series the gasoline and oil consumption are notably low, as is the weight per horse-power.

In the eighteen-cylinder overhead valve Sunbeam-Coatalen aircraft engine of 475 brake horse-power, there are no fewer than half a dozen magnetos. Each magneto is inclosed. Two sparks are furnished to each cylinder from independent magnetos. On this engine there are also no fewer than six carburetors. Shortness of crank-shaft, and therefore of engine length, and absence of vibration are achieved by the linking of the connecting-rods. Those concerned with three-cylinders in the broad arrow formation work on one crank-pin, the outer rods being linked to the central master one. In consequence of this arrangement, the piston travel in the case of the central row of cylinders is 160 mm., while the stroke of the pistons of the cylinders set on either side is in each case 168 mm. Inasmuch as each set of six-cylinders is completely balanced in itself, this difference in stroke does not affect the balance of the engine as a whole. The duplicate ignition scheme also applies to the twelve-cylinder 350 brake horse-power Sunbeam-Coatalen overhead valve aircraft engine type. It is distinguishable, incidentally, by the passage formed through the center of each induction pipe for the sparking plug in the center cylinder of each block of three. In this, as in the eighteen-cylinder and the six-cylinder types, there are two cam-shafts for each set of cylinders. These cam-shafts are lubricated by low pressure and are operated through a train of inclosed spur wheels at the magneto end of the machine. The six-cylinder, 170 brake horse-power vertical type employs the same general principles, including the detail that each carburetor serves gas to a group of three-cylinders only. It will be observed that this engine presents notably little head resistance, being suitable for multi-engined aircraft.

INDICATING METERS FOR AUXILIARY SYSTEMS

The proper functioning of the power plant and the various groups comprising it may be readily ascertained at any time by the pilot because various indicating meters and pressure gauges are provided which are located on a dash or cowl board in front of the aviator, as shown at Fig. 251. The speed indicator corresponds to the speedometer of an automobile and gives an indication of the speed the airplane is making, which taken in conjunction with the clock will make it possible to determine the distance covered at a flight. The altimeter, which is an aneroid barometer, outlines with fair accuracy the height above the ground at which a plane is flying. These instruments are furnished to enable the aviator to navigate the airplane when in the air, and if the machine is to be used for cross-country flying, they may be supplemented by a compass and a drift set. It will be evident that these are purely navigating instruments and only indicate the motor condition in an indirect manner. The best way of keeping track of the motor action is to watch the tachometer or revolution counter which is driven from the engine by a flexible shaft. This indicates directly the number of revolutions the engine is making per minute and, of course, any slowing up of the engine in normal flights indicates that something is not functioning as it should. The tachometer operates on the same principle as the speed indicating device or speedometer used in automobiles except that the dial is calibrated to show revolutions per minute instead of miles per hour. At the extreme right of the dash at Fig. 251 the spark advance and throttle control levers are placed. These, of course, regulate the motor speed just as they do in an automobile. Next to the engine speed regulating levers is placed a push button cut-out switch to cut out the ignition and stop the motor. Three pressure gauges are placed in a line. The one at the extreme right indicates the pressure of air on the fuel when a pressure feed system is used. The middle one shows oil pressure, while that nearest the center of the dash board is employed to show the air pressure available in the air starting system. It will be evident that the character of the indicating instruments will vary with the design of the airplane. If it was provided with an electrical starter instead of an air system electrical indicating instruments would have to be provided.

COMPRESSED AIR-STARTING SYSTEMS

Two forms of air-starting systems are in general use, one in which the crank-shaft is turned by means of an air motor, the other class where compressed air is admitted to the cylinders proper and the motor turned over because of the air pressure acting on the engine pistons. A system known as the “Never-Miss” utilizes a small double-cylinder air pump is driven from the engine by means of suitable gearing and supplies air to a substantial container located at some convenient point in the fuselage. The air is piped from the container to a dash-control valve and from this member to a peculiar form of air motor mounted near the crank-shaft. The air motor consists of a piston to which a rack is fastened which engages a gear mounted on the crank shaft provided with some form of ratchet clutch to permit it to revolve only in one direction, and then only when the gear is turning faster than the engine crank-shaft.

The method of operation is extremely simple, the dash-control valve admitting air from the supply tank to the top of the pump cylinder. When in the position shown in cut the air pressure will force the piston and rack down and set the engine in motion. A variety of air motors are used and in some the pump and motor may be the same device, means being provided to change the pump to an air motor when the engine is to be turned over.

The “Christensen” air starting system is shown at Figs. 252 and 253. An air pump is driven by the engine, and this supplies air to an air reservoir or container attached to the fuselage. This container communicates with the top of an air distributor when a suitable control valve is open. An air pressure gauge is provided to enable one to ascertain the air pressure available. The top of each cylinder is provided with a check valve, through which air can flow only in one direction, i.e., from the tank to the interior of the cylinder. Under explosive pressure these check valves close. The function of the distributor is practically the same as that of an ignition timer, its purpose being to distribute the air to the cylinders of the engine only in the proper firing order. All the while that the engine is running and the car is in motion the air pump is functioning, unless thrown out of action by an easily manipulated automatic control. When it is desired to start the engine a starting valve is opened which permits the air to flow to the top of the distributor, and then through a pipe to the check valve on top of the cylinder about to explode. As the air is going through under considerable pressure it will move the piston down just as the explosion would, and start the engine rotating. The inside of the distributor rotates and directs a charge of air to the cylinder next to fire. In this way the engine is given a number of revolutions, and finally a charge of gas will be ignited and the engine start off on its cycle of operation. To make starting positive and easier some gasoline is injected in with the air so an inflammable mixture is present in the cylinders instead of air only. This ignites easily and the engine starts off sooner than would otherwise be the case. The air pressure required varies from 125 to 250 pounds per square inch, depending upon the size and type of the engine to be set in motion.

ELECTRIC STARTING SYSTEMS

When it is desired to start the engine an electrical connection is established between the storage battery and the motor-generator unit, and this acts as a motor and turns the engine over by suitable gearing which engages the gear teeth cut into a special gear or disc attached to the engine crank-shaft. When the motor-generator furnishes current for ignition as well as for starting the motor, the fact that the current can be used for this work as well as starting justifies to a certain extent the rather complicated mechanism which forms a complete starting and ignition system, and which may also be used for lighting if necessary in night flying.

An electric generator and motor do not complete a self-starting system, because some reservoir or container for electric current must be provided. The current from the generator is usually stored in a storage battery from which it can be made to return to the motor or to the same armature that produced it. The fundamental units of a self-starting system, therefore, are a generator to produce the electricity, a storage battery to serve as a reservoir, and an electric motor to rotate the motor crank-shaft. Generators are usually driven by enclosed gearing, though silent chains are used where the center distance between the motor shaft and generator shaft is too great for the gears. An electric starter may be directly connected to the gasoline engine, as is the case where the combined motor-generator replaces the fly-wheel in an automobile engine. The motor may also drive the engine by means of a silent chain or by direct gear reduction.

Every electric starter must use a switch of some kind for starting purposes and most systems include an output regulator and a reverse current cut-out. The output regulator is a simple device that regulates the strength of the generator current that is supplied the storage battery. A reverse current cut-out is a form of check valve that prevents the storage battery from discharging through the generator. Brief mention is made of electric starting because such systems will undoubtedly be incorporated in some future airplane designs. Battery ignition is already being experimented with.

BATTERY IGNITION SYSTEM PARTS

A battery ignition system in its simplest form consists of a current producer, usually a set of dry cells or a storage battery, an induction coil to transform the low tension current to one having sufficient strength to jump the air gap at the spark-plug, an igniter member placed in the combustion chamber and a timer or mechanical switch operated by the engine so that the circuit will be closed only when it is desired to have a spark take place in the cylinders. Battery ignition systems may be of two forms, those in which the battery current is stepped up or intensified to enable it to jump an air gap between the points of the spark plug, these being called “high tension” systems and the low tension form (never used on airplane motors) in which the battery current is not intensified to a great degree and a spark produced in the cylinder by the action of a mechanical circuit breaker in the combustion chamber. The low tension system is the simplest electrically but the more complex mechanically. The high tension system has the fewest moving parts but numerous electrical devices. At the present time all airplane engines use high tension ignition systems, the magneto being the most popular at the present time. The current distribution and timing devices used with modern battery systems are practically the same as similar parts of a magneto.

INDEX