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2.5_Engine Mounting_rev2012

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33 views

2.5_Engine Mounting_rev2012

Uploaded by

Daniel Souza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Engine Mounting and Isolation

AE Basics Brasil 2012

Rodrigo Costa
August, 2012
Engine Mounting - Basic Requirements

• The mounting system must protect OEM components from


damaging vibration excitation.
• The mounting system withstand normal operating loads and
deflections without damage.
• The mounting system must not induce excessive loads on the
attachment points or block.
• The mounting system must be allow the necessary movements
and deflection without damaging interference.
• The design must consider unusual loads such as shock and impact.
• Redundant provisions may be required in the event of isolator failures.
Types of Engine Mounting
• Rigid (solid mounted) - Primarily used for large engines in stationary
applications with a sub-base that is placed on a massive foundation.
Mounting allows only minimal motion for thermal expansion and
operating deflections of the engine block. Alignment to driven devices
can be controlled very precisely. Also possible with small, structural
engines.
• Semi-Rigid - used when only limited isolation of engine is required or
isolator sub-frame is used. Very common in industrial equipment with
massive frames and for engines with 12 or more cylinders.
• Isolation (soft mounted) - desirable for mobile equipment and with
smaller, high speed engines. The engine and direct attached
components are totally isolated and allowed to move in response to
normal engine vibration excitations. OEM structures need not be as
rigid or massive to control noise and vibration.
Rigid Mounting - Considerations

• For rigid mounting to work effectively the sub-base structures must be


truly ‘rigid’ under common forces to the point of excess.
• Isolation pads are used to attach the sub-base to foundation for larger
engines. These isolators effectively ‘stiffen’ the sub-base and damp
vibrations.
• Block attachments must allow for expansion and normal deflection
under firing forces. This is why slip joints are used on front of very large
engines.
• Rigid mounting of small, structural engines is very advanced. The
adapter design must be coordinated between product engineering and
OEM structural engineers.
Semi - Rigid Mounting

• Degree of isolation varies widely. Often involves major subframes


that allow two levels of isolation.
• Often the only practical choice for large engines in mobile
equipment. Mounting provisions and load levels may not lend
themselves to simple isolation mounting.
• Considerations of shock loading and frame deflection may be as
important as isolation performance.
• May also require isolation of specific machine components such
as cab, control boxes, etc.
Isolation Mounting
• This is the most typical mounting for mobile equipment with engines of
8 cylinders or less.
• Isolation mounting creates separate systems which are isolated from
each other.
• The engine and directly attached components vibrate as a unit and all
components of this system must be capable of handling the vibration
levels. This can include exhaust, intake and cooling components.
• Components that are separated by the isolators are not subject to
engine excitation frequencies and can often be less massive and rigid.
• Any connections between the two systems must allow for free motion.
(Exhaust, intake, etc.)
Engine Vibration Motions

• An isolated engine package is free to move in three directions and


three rotations.
• Vibration forces are reacted by the mass and inertia of as well as
isolator reactions.

yaw

roll

pitch
Engine Vibration - Vertical Shaking

• A four cylinder engine has significant second order shaking forces in


the vertical direction. This will cause pure vertical motion of the
engine as well as some pitch rotation depending on CG location.

Vertical
Engine Vibration - Roll

• Most engines have significant motion due to firing torque reaction to


engine block at firing frequency.
• Engine roll about center of least inertia close to crank axis.
Estimated as axis through the CG of major components.

Roll
Isolation of Four Cylinder Engines

• Unbalanced, In-line, four-cylinder, four-cycle engines are inherently


problematic for isolation mount designers.
• At low speeds the roll shaking forces are not reacted well by engine
inertia. It is difficult to control engine movement yet chose isolators
that are soft enough at roll frequency to isolate well at idle.
Restricting low speed operation is effective.
• At high speeds the engine mass reacts roll more effectively and
higher frequencies are easier to isolate. Here the effect of
unbalanced vertical shaking force dominates.
• Balance shafts reduce the vertical shaking forces.
Vertical and Roll Vibration
Second Order - Four Cylinder Engine

The Effects of Engine Speed


0.014

0.012

0.01
Mils of Deflection

0.008

0.006
Balancer can reduce
0.004

0.002

Roll Vibration
0
900 1100 1300 1500 1700 1900 2100 2300 2500

Engine Speed (RPM)


Engine Isolator Location

• Ideal isolator location would be as close to roll axis as possible for best
roll isolation for given mount stiffness.
• Actual location is usually dictated by mounting pad location and bending
moment limitations.
• Long cantilevers off mounting pads must be avoided.
Avoid long cantilevers
causes – excess moment loads and poor isolation

• Engine Mounts Should Be Located as close to the Roll Axis as


Possible

isolators
Engine Isolator Basics

• SELECTING POWER PLANT MOUNTS:


• Isolators should have large deflection (low spring rate) in the
direction of movement around the roll axis
• Typically this is:
 Vertical for rear mounts
 Horizontal for front mounts
Front Mount Considerations

• Ideal location would be high on block near roll axis. This is seldom
practical.
• If single point front mount is used, the mount must be specially chosen
to be very soft in direction of roll (side to side).
• If mount is soft laterally and has linear stiffness then engine may move
too easily under side loads.
• Focused front mounts allow for low roll stiffness while maintaining
stiffness to pure side loads.
• Vertical isolation characteristics of front mount are not usually critical
for six cylinder engines.
• Preferred mount will be very soft axially to transfer axial forces to rear
mounts.
Front Mount Designs
Note the difference in these two
designs!

Equal Stiffness Design


No air gap
(linear stiffness)
air gap
Non - Linear Design
(provides non linear stiffness)
(much softer lateral)
Front Mount Designs
Where is your isolator?
Rear Mount Considerations

• If isolators are close to flywheel housing they will have lower roll
frequency for a given stiffness.
• Avoid long cantilevers (any direction) off the mounting pads. Try to keep
offset less than bolt spacing of pad.
• Roll isolation performance is determined by vertical stiffness. Axial and
lateral stiffness can be high to assure good location control.
• Soft isolators are often shear designs and will be relatively large
compared to compression designs.
• Remember to consider dynamic loads from all directions, not just
vertical, static loads.
Rear Mount Designs

Note the rebound features!

Focused
rear mounts

Shear type mounts


Isolator Selection

• Manufacturers must be relied on for design verification.


• Most modern isolators use elastomers to give good damping at
reasonable cost.
• Remember ...
– Elastomers in compression are very durable but very stiff.
– Elastomer in tension is not durable may fail catastrophically.
– Rubber in shear is very soft but easily damaged by overload.
Isolator Selection

• Isolators having lower stiffness values (while all other factors


remain constant) will generally lower the natural frequency of the
system and give better isolation.

• Isolators are available in various stiffness and load ratings.

• Isolators having higher stiffness values (while all other factors


remain constant) will generally raise the natural frequency of the
system.

• Lower stiffness isolators have lower capacity for given size. Often
referred to by durometer.
Isolator Selection

• Non-linear mount stiffness is very desirable.

• Improper engine isolation may result in higher vibration levels at


the engine when compared to a suspended engine.

• The natural frequencies of the mounting system must be “tuned”


according to the weight and vibration characteristics of the engine
package.

• Isolators which are too soft will allow the engine to move
excessively in the chassis. They also may not have enough load
capacity and experience fatigue failures.
Isolator Selection

• Moving isolators closer to the natural roll axis of the system (while
all other factor remain constant) will tend to lessen the vibration
transmitted to the frame.

• Most isolators will have a maximum load rating defined by the


supplier, and some suppliers derate the capacity of the isolators for
some applications such as Construction or Off-Highway.

• Good shear isolators incorporate provisions protecting the


elastomer from damage due to overload (snubbers).
Isolator Selection

• Isolators with the elastomer bonded to the working faces tend to


have longer, more consistent performance.

• Some isolators require careful assembly of proper spacers and


control of mounting bores to work effectively.

• Isolation curves force transferred for infinite stiffness base. This


only happens if the machine frame is much stiffer than isolator.

• All attachments between engine and operator cab must be soft to


avoid "short circuiting" the mount system. This includes exhaust,
coolant and fuel and other plumbing, and other mechanical
connections to the chassis.
Alternative Mounting Designs

• Clever packaging can improve isolation.


• An alternative three point system is shown below. Commonly seen in
light duty automotive and four cylinder compact equipment. Requires
side pads near engine CG.

Focused Pair near engine CG

Single Rear
Pairs of Focused Mounts

• Focus must be calculated based on mount stiffness ratio, the real focus
is not the geometric focus.
• Effectively simulates a mount at the elastic center.

Note feature (bolt w/clearance) to protect isolators from excessive rebound


Datasheet Requirements
QSM11
Troubleshooting Engine Mount Issues

• Try to determine details of the complaint from persons most


familiar. What are symptoms? When does it occur?
• If complaint is at idle, check idle speed. Adjust speed and see if
problem goes away.
• Check for good isolation across mounts at worst case speed,
focus on direction where vibration is most significant (i.e. there is
no need for good isolation in directions where there is no
excitation)
• Check isolators for proper assembly. Look for ‘shorts’ across
isolator, missing spacers, snubber contact, etc.
• Check for vibration transmission through controls, air, fluid and
exhaust connections.
• If problem occurs under load then make sure there is are not
contact points when isolators deflect.
Mounting – Engine Mount Location
Mounting – Front Mount
Mounting – Flywheel Housing
Mounting – Front Isolator
Mounting – Rear Isolator
Isolator Deflection Curves - Lord Catalog

27

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