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This rotary engine design was inspired by the Mazda RX-series engines, known for their compact and high-revving nature. My focus was on optimizing rotor geometry and improving the efficiency of the engine's apex seals, intake, and exhaust ports. Using SolidWorks for design, I aimed to create a rotary engine model with enhanced performance and reliability.
Internals
Internals
Exploded view and the internal components of the rotary engine, highlighting the simplified yet effective design.
Cross-Sectional View of the Rotary Engine and Rotor
Cross-Sectional View of the Rotary Engine and Rotor
Cross-sectional view demonstrating the movement of the rotor and the unique triangular combustion chamber design, which contributes to the engine's compact size and high revving capability.
Side Cross-Section
Frontal Cross-section
Rotor Assembly
Key Design Features
Key Design Features
The rotor was designed with improved geometry to ensure smoother operation and more efficient combustion. Apex seals, often a weak point in rotary engines, were optimized using high-performance materials to reduce wear and maintain proper sealing, enhancing the engine's overall reliability. Additionally, the intake and exhaust ports were repositioned to optimize airflow, with larger intake ports allowing for increased air volume and improved throttle response. A wider exhaust port was incorporated to reduce backpressure, maximizing power output.
To further improve the engine's performance, lightweight materials were selected for both the rotor and housing, reducing the overall weight and creating a compact design. This minimized the engine’s footprint, making it ideal for performance applications where space and weight are critical. The engine was also designed with advanced cooling pathways and materials to effectively dissipate heat during operation, addressing one of the common challenges in rotary engines—overheating during extended high-performance use.
Design Challenges
Design Challenges
One of the major challenges was improving the durability of the apex seals, a known issue in rotary engines. After researching different materials, I chose a high-performance alloy that reduced friction while maintaining tight sealing, significantly improving the engine’s reliability.
Lessons Learned
Lessons Learned
This project provided valuable insights into the unique dynamics of rotary engines, particularly in optimizing airflow and managing thermal challenges. The experience also deepened my understanding of material selection for high-performance applications.
Technical Specifications
Technical Specifications
Engine Type: 2-Rotor Wankel Rotary Engine, DOHC equivalent in terms of power cycles (no conventional valves).
Displacement: 1,308 cc (1.3 liters total displacement, 654 cc per rotor).
Bore x Stroke: Rotary engines do not have a traditional bore and stroke. Instead, rotor width and eccentric shaft stroke define displacement.
Rotor width: 80 mm
Eccentric shaft stroke: 15 mm.
Compression Ratio: 9.0:1 (varies by model and tuning).
Valve Train: Rotary engines don’t use a valve train with traditional valves. Instead, they have intake and exhaust ports located on the rotor housing or side housings.
Engine Weight: 120–140 kg (264–308 lbs).
Block Material: Aluminum housing (in some variants, iron or composite materials are used for durability and cooling purposes).
Cylinder Head Material: Rotary engines do not have a traditional cylinder head. The rotor housing is made from aluminum or cast iron, depending on the design.
Oil Capacity: 4.5–6 liters (rotary engines consume oil by design, requiring lubrication for the apex seals).
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