Weight and Drivetrain Optimization via Fuel Pump & Vacuum Pump Drive Integration on Engine Camshaft in a Pushrod Type Valve Actuated Engine

Abstract

<div class="section abstract"><div class="htmlview paragraph">In the realm of modern powertrains, the paramount objectives of weight reduction, cost efficiency, and friction optimization drive innovation. By streamlining drive trains through component minimization, the paper introduces a groundbreaking approach: the integration of fuel pump and vacuum pump drive systems into the main camshaft of a two-valve-per-cylinder push-rod actuated 4-cylinder diesel engine. This innovation is poised to concurrently reduce overall weight, lower costs, and minimize drive losses. The proposed integration entails the extension of the camshaft with a tailored slot, accommodating a three-lobed cam composed of advanced materials. This novel camshaft configuration enables the unified propulsion of the oil pump, vacuum pump, fuel pump, and valve train, effectively consolidating functions and components. The integrated camshaft design is subject to meticulous evaluation, ensuring its capacity to manage higher power transmission and accommodate multiple connected drives. Design verification simulations encompassing high cycle fatigue and timing drive dynamics validate its functionality and safety. Physical validations, including overload and cyclic load testing, confirm the enhanced camshaft's robustness and reliability. The iterative refinement of the design throughout development bolsters fatigue life and strength, meticulously addressing critical failure modes. This rigorous approach culminates in substantial weight reduction ~58% in drive train alone, reflecting in cost savings, while concurrently diminishing service costs. The integration's broader impact encompasses the elimination of a significant sub-assembly station, streamlining manufacturing and aligning seamlessly with design-for-manufacturing principles. In summary, the integration of fuel pump and vacuum pump drives into the main camshaft stands as a groundbreaking innovation, addressing weight, cost, and friction while modernizing a typical conventional engine. The synergy of design innovation, simulation validation, and manufacturing enhancement marks a transformative stride in the automotive industry.</div></div>