As4-piston-2-cycle-engine-lg seen in the attached working model, the Gen II has reduced the crank shafts by ½ and doubled the pistons per engine as compared to the Gen I. The product design shown is a 1.2 liter two-cycle engine that is only 24 inches by 12 inches by 5 inches. Its weight will be under 75 lbs. as a gas engine and 95 lbs as a diesel. This two-cycle engine is fuel injected and does not require valves or oil in the gas. Four unique “cylinder rings” have been added to the engine keeping each dual piston in place and keeping the oil in the crank cases. Air pumps on either side of the upper pistons and oil pumps at the bottom of the lower pistons allow for a fully enclosed system.

This design is also water cooled and can be made into a 4 cycle with the addition of valves. The ideal application for this engine would be a motor-generator set for series hybrid EVs due to its very light weight and power density. The design does, however, require two crankshafts to ensure that piston can travel straight up and down in the cylinder. This setup ensures that there is little friction due this parallel movement of the piston to the cylinder walls. The piston head is cooled by a unique air intake that passes through the top of the piston head and then into the cylinder.

The air pumps, located in the upper portion of the engine block, push air in both travel directions and supply over 120% of the volume of air that is needed in the cylinder cleaning out the cylinder of exhaust. A new exhaust turbo pump will be added later to allow for even higher RPMs and horse power to this two cycle engine. This 75 lb engine is expected to put out over 200 HP in its final design.

Reduced Weight and Expense

The Gen II engine block is extruded and not cast, reducing both cost and weight. Gen IV, as can be seen on the first page of the web site, is a unique 3D sand cast molded part with a number of design benefits. It is expected that the final design of the block will incorporate both concepts.

Gen 2 Piston

Gen II uses an air flow through piston head allowing for greater cooling at high engine RPMs

Efficiency

The internal components of the Gen II engine are shown in this assembly. With this design, little space is wasted inside the engine. The dual piston sets allow load sharing by the mechanical structure components and the crankshaft bearings producing a balanced pressure on them from the push and pulling of the four push rods. This balance adds to component and bearing life and with the dual sets of opposed pistons, no counter balances are needed on the crank shafts reducing vibration and weight. Gen IV will use a supercharger in place of the air pumps, but both designs have applications in the field.