FORM 2
THE PATENTS ACT 1970
(39ofl970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(See Section 10; rule 13)
TITLE OF THE INVENTION
A novel Inline two cylinder direct injection high pressure common rail four-stroke reciprocating piston internal combustion turbocharged diesel engine
APPLICANTS
TATA MOTORS LIMITED, an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
INVENTORS
Mr. Milind D. Peshave, Mr.Niraj R. Dharkar Indian nationals
of TATA MOTORS LIMITED,
an Indian company having its registered office
at Bombay House, 24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
PREAMBLE TO THE DESCRIPTION
The following complete specification particularly describes the invention and the manner in which it is to be performed.

TITLE:
A novel Inline two cylinder direct injection high pressure common rail four-stroke reciprocating piston internal combustion turbocharged diesel engine.
FIELD OF INVENTION:
This invention relates to internal combustion diesel engine and more particularly to two cylinder inline, four stroke, diesel, direct injection common rail, reciprocating piston, Turbocharged, intercooled, and overhead camshaft engine for small car and light commercial vehicle application
BACKGROUND OF INVENTION:
Conventionally most of the small passenger cars and light commercial vehicles are powered by 3 or 4 cylinder, internal combustion, four stroke, and reciprocating engines with diesel, gasoline or other suitable alternate fuel. Where as no engine in two cylinder inline configuration with high pressure direct injection common rail diesel configuration is in use for passenger car and light commercial vehicle application. This invention will meet all the diverse and critical requirements by integrating the fine tuned components for its objective which previously not possible to done.
GB 1219558 & 1285915 relates to two cylinder four stroke cycle reciprocating piston internal combustion V engines (V angle concept of block).
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Compared to above said two prior arts our invention will be with simpler structure with inline block with integration of common rail fuel injection diesel concept.
Multifold performance requirements such as high performance deliverables, compactness & robustness for small passenger cars and light commercial vehicles are putting diverse requirements on engine design.
The aim of the present invention is to provide the compact, quiet, robust engine to deliver the require output applicable for the passenger car and light commercial vehicle with focus on achieving the best in class fuel efficiency with capability to meet the future emission norms with required margins.
OBJECT OF INVENTION:
The main object of this invention is to have high performance deliverable, compact & robust internal combustion diesel engine suitable for small car and light commercial vehicle application.
Another object of this invention is to have an internal combustion engine with high fuel efficiency with reduced emissions.
Yet another object of this invention is to have an internal combustion engine with reduced pass by noise level when assembled on passenger car or light commercial vehicle
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SUMMARY OF INVENTION:
This novel inline two cylinder direct injection high pressure common rail four stroke reciprocating piston internal combustion turbocharged diesel engine has got integration of following key features:
Air charging system: including piston bowl, special port design for smooth and efficient air passage in cylinder head and inlet manifold & incorporating turbocharger with intercooler for ensuring the availability of maximum air flow with controlled temperature combines excellent flow performance with encouraging swirl capabilities for good air flow acceptance.
Electronically controlled fuel injection system: High pressures injection system (through the electronic pump high pressure of 1400 to 1500 bar will ensures optimum use of fuel) will assist in better atomization of fuel and hence benefits combustion. Instead of having to build up pressure before each individual injection, the fuel is stored in the accumulator (common rail) and kept under constant pressure. Required quantity at required time; fuel is injected in the combustion chamber with the precise control of electronic control unit as per the optimized map designed to meet the severe challenge of two cylinder internal combustion engine.
Design of rotating parts : Crankshaft design ensures the single firing at every revolution additionally transfer of drive ( Gear drive) from crankshaft to balancer shaft ensures rotation of balancer shaft at the same speed of crankshaft are the key parameters for the effective functioning of two cylinder engine performance acceptance.
Appropriate design of Lubrication, Water circuit & other accessories to ensure the correct functioning of an engine at all the operating range.
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DETAILED DESCRIPTION OF PREFERRED EMBODIMENT:
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same, Figure 1 shows an engine with a view looking from the front & left hand side of an engine , Figure 2 shows a view from the front & right hand side of an engine, Figure 3 shows a novel inline two cylinder direct injection high pressure common rail four stroke reciprocating piston internal combustion diesel engine where as Figure 4 shows a part of air charging system.
Now with reference to figure 1& 2 where in Cylinder block (1) is provided with two bores in the inline configuration and adequate provisions for water jacket & oil flow accommodates reciprocating assembly of piston and connecting rod. Bed plate (2) along with cylinder block provides support to crank shaft & balancer shaft said balancer shaft is driven by a crank shaft through gear drive. This assembly of cylinder block, bedplate and oil pan (3) ensures the rigidity of structure along with reduction in overall vibration level of the engine.
A flow optimized cylinder head (4) provides excellent flow performance with encouraging swirl capabilities for good pilot injection acceptance. Two valves per cylinder with valve actuation by direct camshaft is assembled in cylinder head. An efficient charging system includes integrated inlet manifold with flow optimized ports and cylinder head cover (5) provides compactness in the design. Optimized exhaust gas recirculation involving exhaust gas circulation valve (6) and exhaust gas circulation cooler with electronic control strategy for reduction of emission. High pressure common rail fuel injection system with high pressure pump (7), fuel accumulator (common rail) (8) and injectors (9) provides best pre-conditions for a most flexible injection strategy, balancing the requirement of emission, fuel consumption & acoustic behavior of the engine as well as the support of diesel after treatment systems (10) turbocharger (11)
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integral with exhaust manifold having waste gate configuration capable of delivering the required boost pressure optimized to suit the this engine requirement with the appropriate intercooling (Intercooler suitably mounted on the vehicle) to ensure the optimum air temperature in the inlet manifold provides the maximum air flow & ensures the maximum power output from an engine.
The illustrated two cylinder inline engine has two pistons with optimized cavity connected to crankshaft with individual connecting rods present in cylinder block (1) rotating at 360 degree phase difference to ensure single power stroke in each revolution and assures smooth power flow with the help of balancer shaft rotating at the same speed of crankshaft
Engine accessories represented by (12), (13) & (14) are starter motor, A/C compressor, & alternator respectively will meet the vehicle level requirements of passenger car & light commercial vehicle. Front engine accessory drive layout (15) is suitably designed, using idler (16) & tensioner (17) to provide the drive from crankshaft pulley (18) to all the accessories.
Lubrication of the engine is through the pressurized system generated by the oil pump driven by gear drive, present in the front timing belt cover (19). Pressurized oil flows through the oil filter & cooler assembly (20) to the respective positions.
Cooling of the engine is through the pressurized system generated by the water pump driven by timing belt drive, present in the front timing belt cover (19). The water is distributed to the respective positions from the water box (21).
Figure 3 shows cylinder block with two cylinders in the inline configuration (22) which accommodates the piston with bowl & pin (23), connecting rod (24) & crankshaft (25) supported at the bottom by bedplate (26). High pressure fuel (1400 to 1500 bar) from
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common rail (8) is injected in the combustion chamber through injectors (9). Gear drive (27) from crankshaft to balancer shaft ensures positive & equal revolutions per minutes at balancer shaft.
Figure 4 shows cylinder head (4) and integrated inlet manifold with head cover (5) with a view of cylinder head port (28) for smooth efficient air passage and arrangement of valve actuation by overhead camshaft (29).
This invention will provide state of the art performance for noise, reliability, emission & fuel efficiency.
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.
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WE CLAIM:
1. A novel Inline two cylinder direct injection high pressure common rail four stroke reciprocating piston internal combustion turbocharged diesel engine comprising:
a cylinder block with two bores in the inline configuration accommodating the piston with bowl and connecting rod arrangement said connecting rod is connected to a crank shaft supported on a bed plate; said cylinder block have a cylinder head and which supports two valves per cylinder and are actuated directly by overhead camshaft;
air charging system includes inlet manifold integrated with cylinder head cover fitted on a said cylinder head which have flow optimized ports, and exhaust gas recirculation system comprising of electronically controlled valve & a cooler fitted between exhaust manifold & inlet manifold, and turbocharger integrated with exhaust manifold mounted on the cylinder head to have a required air flow for combustion;
a high pressures injection system consisting of high pressure pump mounted on the said cylinder block, common fuel rail and two injectors mounted on the said cylinder head to assist in better atomization of fuel; the fuel is stored in the said rail and kept under constant pressure with the help of pressure regulator mounted on the rail; fuel is then injected in the combustion chamber with the precise control of electronic control unit as per requirement of the engine.
2. Internal combustion engine as claimed in claim 1 wherein the volume of a said cylinder is 800 (+/- 100) cubic centimeter and the fuel injection pressure is 1400 to 1500 bar.
3. Internal combustion engine as claimed in claims 1 or 2 wherein the said engine have forced circulation water-cooled and forced oil lubrication system.
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4. Internal combustion engine as claimed in claims 1 to 3 wherein two crank pins are located at 360 degree phase difference on the said crankshaft to ensure one power stroke at each cycle.
5. Internal combustion engine as claimed in claims 1 to 4 wherein a balancer shaft is connected to the said crank shaft through a gear drive thereby rotating the balancer shaft at the same speed of crankshaft.
6. Internal combustion engine as claimed in claims 1 to 5 wherein said engine have optimal combustion chamber with a compression ratio of 17.5(+/- 1.0): 1 and peak firing pressure of 160 (+/- 10) bar.
7. Internal combustion engine as claimed in claims 1 to 6 used in passenger car.
8. Internal combustion engine as claimed in claim 1 to 6 wherein the said engine is provided with intercooler which is mounted on the vehicle to minimize the temperature of pressurized air.
9. Internal combustion engine as claimed in claims 1 to 6 and 8 used in light commercial vehicle.
10. A novel Inline two cylinder direct injection high pressure common rail four stroke
reciprocating piston internal combustion turbocharged diesel engine substantially as
herein described with reference to the figure 1 to 4 of the accompanying drawings.
Dated this 7th day of February 2007
TATA MOTORS LIMITED By their Agent and Attorney
(KARUNA GOLERIA) of DePENNING & DePENNING
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ABSTRACT
A novel Inline two cylinder direct injection high pressure common rail four-stroke reciprocating piston internal combustion turbocharged diesel engine
This invention relates to a novel Inline two cylinder direct injection high pressure common rail four-stroke reciprocating piston internal combustion turbocharged diesel engine comprising a cylinder block with two bores in the inline configuration accommodating the piston with bowl and connecting rod arrangement said connecting rod is connected to a crank shaft supported on a bed plate; said cylinder block have a cylinder head and which supports two valves per cylinder and are actuated directly by overhead camshaft, air charging system includes integrated inlet manifold fitted on a said cylinder head which have flow optimized ports; and exhaust gas recirculation system comprising of electronically controlled valve & a cooler fitted between exhaust manifold & inlet manifold, and turbocharger Integrated with exhaust manifold mounted on the cylinder head to have a required air flow for combustion and a fuel injection system to assist in better atomization of fuel and hence benefits combustion. In this instead of having to build up pressure before each individual injection, the fuel is stored in the fuel common rail and kept under constant pressure and a correct quantity of fuel is injected in the combustion chamber with the precise control of electronic control unit as per requirements of the engine.
Fig.l