The Wankel engine (, ) is a type of internal combustion engine using an eccentric rotary design to convert pressure into rotating motion. The concept was proven by German engineer Felix Wankel, followed by a commercially feasible engine designed by German engineer Hanns-Dieter Paschke. The Wankel engine's rotor is similar in shape to a Reuleaux triangle, with the sides having less curvature. The rotor spins inside a figure-eight-like housing around a fixed gear. The midpoint of the rotor moves in a circle around the output shaft, rotating the shaft via a cam.
In its basic gasoline-fuelled form, the Wankel engine has lower thermal efficiency and higher exhaust emissions relative to the four-stroke reciprocating engine. This thermal inefficiency has restricted the Wankel engine to limited use since its introduction in the 1960s. However, many disadvantages have mainly been overcome over the succeeding decades following the development and production of road-going vehicles. The advantages of compact design, smoothness, lower weight, and fewer parts over reciprocating internal combustion engines make Wankel engines suited for applications such as , auxiliary power units (APUs), loitering munitions, aircraft, personal watercraft, , , Auto racing, and automotive range extenders.
In 1954, NSU agreed to develop a rotary internal combustion engine with Wankel based upon his supercharger design. Since Wankel was known as a "difficult colleague", the development work for the DKM was carried out at Wankel's private Lindau design bureau. According to John B. Hege, Wankel received help from his friend Ernst Höppner, who was a "brilliant engineer".
Due to its complicated design with a stationary center shaft, the DKM engine was deemed impractical. Wolf-Dieter Bensinger explicitly mentions that proper engine cooling cannot be achieved in a DKM engine, and argues that this is the reason why the DKM design had to be abandoned.
Wankel obtained US patent 2,988,065 on the KKM engine on 13 June 1961.
In 1963, NSU produced the first series-production Wankel engine for a car, the KKM 502. It was used in the NSU Spider sports car, of which about 2,000 were made. Despite its "teething troubles", the KKM 502 was a powerful engine with decent potential, smooth operation, and low noise emissions at high engine speeds. It was a single-rotor peripheral port engine with a displacement of , a rated power of at 6,000rpm and a brake mean effective pressure (BMEP) of .
In the early days, unique, dedicated production machines had to be built for different housing dimensions. However, patented designs such as , G. J. Watt, 1974, for a "Wankel Engine Cylinder Generating Machine", , "Apparatus for machining and/or treatment of trochoidal surfaces" and , "Device for machining trochoidal inner walls", and others, solved such production issues.
Wankel engines have a problem not present in reciprocating piston four-stroke engines in that intake, compression, combustion, and exhaust occur at fixed locations, causing a very uneven thermal load on the rotor housing.
Problems arose during research in the 1950s and 1960s as engineers were faced with what they called "chatter marks" and "devil's scratch" in the inner epitrochoid surface, resulting in chipping of the chrome coating on the trochoidal surfaces. They discovered that the cause was the apex seals reaching a resonating vibration, and the problem was solved by reducing the thickness and weight of the apex seals as well as using more suitable materials. Scratches disappeared after introducing more compatible materials for seals and housing coatings. Kenichi Yamamoto experimentally lightened apex seals with holes, identifying weight as the main cause and leading Mazda to use aluminum-impregnated carbon apex seals in their early production engines. NSU used carbon antimony-impregnated apex seals against a chrome housing surface; upon developing an "Elnisil" coating to production maturity, it returned to a metal sealing strip for the Ro 80. Mazda continued to use a chrome surface, but applied to a steel jacket in the aluminum housing. This allowed Mazda to return to the 3mm and later even 2mm thick metal apex seals.Yamamoto, Kenichi (1971). Rotary Engine. Toyo Kogyo. Page 60-61 Another early problem was the build-up of cracks in the stator surface near the plug hole, which was eliminated by installing the spark plugs in a separate conductive copper insert instead of screwing them directly into the block housing.
Toyota found that substituting Glow plug for leading-area spark plugs improved low-RPM partial-load specific fuel consumption by 7%, as well as emissions and idle performance.SAE paper 790435 A later alternative solution to spark plug boss cooling was a variable coolant velocity scheme for water-cooled rotaries, which was patented by Curtiss-Wright and saw widespread use., M. Bentele, C. Jones, F. P. Sollinger, 11/7/61 and , C. Jones, R. E. Mount, 4/29/63 and , C. Jones, 7/27/65 These approaches did not require a copper insert, but did not preclude its use. Ford tested a Wankel engine with the plugs placed in the side plates instead of the housing working surface (, 1978).
All practical Wankel engines are Otto cycle (i.e., four-stroke) engines, with each of the three rotor faces undergoing its own intake, compression, expansion, and exhaust cycles. The shape of the rotor between the fixed apices is to minimize the volume of the geometric combustion chamber and maximize the compression ratio, respectively.For a detailed calculation of the curvature of a circular arc approximating the optimal Wankel rotor shape, see In theory, two-cycle engines are possible, but they are impractical because the intake gas and the exhaust gas cannot be properly separated. As the Diesel cycle with its Diesel engine cannot be used in a practical Wankel engine,
Wankel engines have a much lower degree of irregularity relative to a reciprocating engines, leading to much smoother operation. This is because the Wankel engine has a lower moment of inertia and more uniform torque delivery. For example, a two-rotor Wankel engine runs more than twice as smoothly as a four-cylinder piston engine.
A peripheral intake port results in the highest mean effective pressure throughout the RPM range (though moreso at high RPM and particularly if rectangularSAE Paper 950454 Page 7); however, side intake porting produces a more steady idle,Yamamoto, Kenichi. Rotary engine, fig 4.26 & 4.27, Mazda, 1981, p. 46. because it helps to prevent blow-back of burned gases into the intake ducts, which causes a "misfire" that manifests as alternating cycles of successful and unsuccessful mixture ignition. Peripheral porting is also linked to worse partial-load performance. Early work by Toyota led to the addition of a fresh air supply to the exhaust port. It also proved that a reed valve in the intake port or ductSAE paper 720466, Ford 1979 patent improved low-RPM partial-load performance of Wankel engines by preventing blow-back of exhaust gas into the intake at the cost of a slight loss of top-end power. Elasticity is improved with a greater rotor eccentricity, analogous to a longer stroke in a reciprocating engine.
Wankel engines operate better with a low-pressure exhaust system. Higher exhaust back pressure reduces mean effective pressure, especially in peripheral intake port engines. The Mazda RX-8's Renesis engine improved performance by doubling the exhaust port area relative to earlier designs, and there have been studies of the effect of intake and exhaust piping configuration on the performance of Wankel engines.Ming-June Hsieh et al. SAE papers Side intake ports, as used in the Renesis, were first proposed by Hanns-Dieter Paschke in the late 1950s. Paschke predicted that precisely calculated intake ports and intake manifolds could make a side port engine as powerful as a peripheral port engine.
Among the alloys cited for Wankel housing use are A-132, Inconel 625, and 356 treated to T6 hardness. Several materials have been used for plating the housing working surface, Nikasil being one. Citroën, Daimler-Benz, Ford, A P Grazen, and others applied for patents in this field. For the apex seals, the choice of materials has evolved along with the experience gained, from carbon alloys, to steel, ferritic stainless, ferrotitanium with carbon, and other materials.
Leaded petrol was the predominant type of gasoline available in the first years of the Wankel engine's development. Lead is a solid lubricant, and leaded gasoline is designed to reduce the wearing of seals and housings. Early Wankel engines had an oil supply that only provided lubrication where leaded gasoline was insufficient. As leaded gasoline was being phased out, Wankel engines needed an increased mix of oil in the fuel to provide lubrication to critical engine parts. An SAE paper by David Garside extensively described Norton's choices of materials and cooling fins.
The problem of clearance for hot rotor apices passing between the axially closer side housings in the cooler intake lobe areas was dealt with by using an axial rotor pilot radially inboard of the oil seals, plus improved inertia oil cooling of the rotor interior (C-W , C. Jones, 5/8/63, , M. Bentele, C. Jones. A.H. Raye. 7/2/62), and slightly "crowned" apex seals (with a different height in the center than the ends).Kenichi Yamamoto, Rotary Engine 1981, Page 50
Direct injection stratified charge engines can be operated with fuels with particularly low octane numbers, such as diesel fuel, which only has an octane number of around 25.SAE Paper 2001-01-1844/4263 Direct injection stratified charge wankel enginesDirect Injection Stratified Charge Rotary Engine Zachary Steven Votaw .A., Wright State University, 2011 p. 6 As a result of worse efficiency, a Wankel engine with peripheral exhaust porting has a larger amount of unburnt Hydrocarbon (HC) released into the exhaust.
The Wankel engine has a significantly higher (ΔtK>100 K) exhaust gas temperature than a reciprocating Otto engine, especially under low- and medium-load conditions. This is because of the higher combustion frequency and slower combustion. Exhaust gas temperatures can exceed under high load at engine speeds of 6000 rpm. To improve the exhaust gas behavior of the Wankel engine, an exhaust manifold reactor or catalytic converter may be used to reduce hydrocarbon and carbon monoxide emissions.
Mazda uses a dual ignition system with two spark plugs per chamber. This both increases power output and reduces HC emissions. At the same time, HC emissions can be lowered by reducing the pre-ignition of the T leading plug relative to the L trailing plug. This leads to internal afterburning and reduces HC emissions. On the other hand, the same ignition timing of the two plugs leads to higher energy conversion. Hydrocarbons adhering to the combustion chamber wall are expelled into the exhaust at the peripheral outlet.Rotary Engine', Kenichi Yamamoto; Toyo Kogyo, 1971 lower HC emisions with dual ignition with leading and trailing spark plug, p. 104Rotary Engine', Kenichi Yamamoto; Toyo Kogyo, 1971 lower HC emisions with dual ignition with leading and trailing spark plug, Fig.13.9 p. 141- Mazda used 3 spark plugs per chamber in their racing R26B engine. The third spark plug ignites the mixture in the trailing side before the "squish" is generated, causing the mixture to burn completely and also speeding up flame propagation, which improves fuel consumption.Mazda Motor Corp.: Ritsuharu Shimizu, Tomoo Tadokoro, Toru Nakanishi, and Junichi Funamoto Mazda 4-Rotor Rotary Engine for the Le Mans 24-Hour Endurance Race SAE Paper 920309 Page 7
According to Curtiss-Wright research, the factor that controls the amount of unburnt hydrocarbons in the exhaust is the rotor surface temperature, with higher temperatures resulting in fewer hydrocarbons in the exhaust. Curtiss-Wright widened the rotor, keeping the rest of the engine's architecture unchanged, thus reducing friction losses and increasing displacement and power output. The limiting factor for this widening was mechanical, particularly shaft deflection at high engine speeds.SAE paper 710582 Quenching is the dominant source of hydrocarbons at high speeds and leakage at low speeds. Using side porting, which allows the exhaust port to close around top dead centre, reduces intake and exhaust overlap and thus improves fuel consumption.
Mazda's RX-8 with the Renesis engine met the in 2004. This was mainly achieved by using side porting: The exhaust port, which in earlier Mazda Wankel engines was located in the rotor housing, was moved to the side of the combustion chamber. This approach allowed Mazda to eliminate overlap between intake and exhaust port openings while simultaneously increasing the exhaust port area. This design improved combustion stability in the low-speed and light load range, and reduced HC emissions by 35–50% compared to a peripheral exhaust port Wankel engine. However, the RX-8 was not improved to meet Euro 5 emission regulations, and it was discontinued in 2012. The new 8C engine in the Mazda MX-30 R-EV meets the Euro 6d-ISC-FCM emissions standard.
The rotor path may be integrated via the eccentricity as follows:
Therefore,
For convenience, may be omitted because it is difficult to determine and small:
A different approach to this is introducing as the farthest, and as the shortest parallel transfer of the rotor and the inner housing and assuming that and . Then,
Including the parallel transfers of the rotor and the inner housing provides sufficient accuracy for determining chamber volume.
If is the number of chambers considered for each rotor and the number of rotors, then the total displacement is:
If is the mean effective pressure, the shaft rotational speed and the number of shaft revolutions needed to complete a cycle ( is the frequency of the thermodynamic cycle), then the total power output is:
With these values, a single-rotor Wankel engine produces the same average power as a single-cylinder two-stroke engine, with the same average torque and the shaft running at the same speed, operating the unitary Otto cycle at triple the frequency.
If power is to be derived from BMEP, the four-stroke engine formula applies:
With this values, a single-rotor Wankel engine produces the same average power as a two-cylinder four-stroke engine, with the same average torque and the shaft running at the same speed, operating the unitary Otto cycles at 3/2 the frequency.
With these values, a single-rotor Wankel engine produces the same average power as a three-cylinder four-stroke engine, with 3/2 of the average torque and the shaft running at 2/3 the speed, operating the unitary Otto cycles at the same frequency:
|
|