A harmonic damper is a device fitted to the free (accessory drive) end of the crankshaft of an internal combustion engine to counter torsional and resonance vibrations from the crankshaft. This device must be an interference fit to the crankshaft in order to operate in an effective manner. An interference fit ensures the device moves in perfect step with the crankshaft. It is essential on engines with long crankshafts (such as straight-six or straight-eight engines) and V8 engines with cross plane cranks, or V6 and straight-three engines with uneven firing order. Harmonics and torsional vibrations can greatly reduce crankshaft life, or cause instantaneous failure if the crankshaft runs at or through an amplified resonance. Dampers are designed with a specific weight (mass) and diameter, which are dependent on the damping material/method used, to reduce mechanical Q factor, or damp, crankshaft resonances.
A harmonic balancer (sometimes called crankshaft damper, torsional damper, or vibration damper) is the same thing as a harmonic damper except that the balancer includes a counterweight to externally balance the rotating assembly. The harmonic balancer often serves as a pulley for the accessory drive belts turning the alternator, water pump and other crankshaft driven devices. [1]
The need for a damper will depend on the age of the engine design, its manufacture, strength of components, usable powerband, rev range and, most importantly,[ citation needed ] the quality of the engine's tune. The engine's tune especially in computer controlled applications can have a dramatic effect on durability,[ citation needed ] the aggressiveness of the tune puts the engine at risk of detonation which can be catastrophic to all rotating assembly components. Modern (roughly 1988+) DOHC, SOHC flat 4, flat 6, flat 8, and flat-plane V8 have no need for this device. With or without the presence of a damper, a crankshaft will act as a torsional spring to some extent. Impulses applied to the crankshaft by the connecting rods will "wind" this spring, which will respond (as a spring–mass system) by unwinding and re-winding in the opposite direction. This crankshaft winding will usually be damped out naturally. However, at certain crankshaft rotational speeds, such winding can overlap with the crankshaft's natural resonant frequency, thereby increasing the frequency's amplitude and possibly leading to crankshaft damage.
Each time a cylinder fires, the force of the combustion is imparted to the crankshaft rod journal. The rod journal deflects in a torsional motion to some degree under this force. Harmonic vibrations result from the torsional motion imparted on the crankshaft. These harmonics are a function of many factors including frequencies created by the actual combustion and the natural frequencies the metals make under the stresses of combustion and flexing. In some engines, the torsional motion of the crankshaft at certain speeds can synchronize with the harmonic vibrations, causing a resonance. In some cases the resonance may stress the crankshaft to the point of cracking or complete failure.
The harmonic balancer helps minimize torsional crankshaft harmonics and resonance. The damper is composed of two elements: an inertia mass and an energy dissipating element. Most often made of rubber, this element may be composed of a synthetic elastomer, a clutch, a spring or fluid. The mass counteracts the torsional crank motions and in concert with the energy dissipating element absorbs the harmonic vibrations.
An OEM damper consists of an outer mass bonded/vulcanized to an inner hub. An aftermarket performance damper consists of a mass which is attached/mounted to a housing (steel, aluminum, titanium, etc.) based on the different types of damper and where the mass is controlled differently. The first three use older technology; First is the liquid type damper which surrounds the mass immersed in the housing which is then bonded or welded together. Second is the o-ring type which surrounds the mass with a number of o-rings as it sits in its housing. Third is the friction type which has clutches and spring acting on the mass inside the outer housing. Fourth is the newest type in which the mass sits over and is attached an elastomer ring which is then attached to the outer housing. The crankshaft and damper together become (in its torsional response) a spring–mass–damper system again which can only occur by the two being interference fit together.
Over time engine development has continually advanced in almost all areas from material, operation, and function. Many of the advances were led by the Japanese manufacturers as they have made quality and durability the cornerstone of their programs. The Japanese advanced the proliferation of forged crankshafts with rotating assemblies at 0 gram balance. Forged crankshafts are much stronger and are significantly less apt to exhibit detrimental torsional crankshaft movement which also mitigates harmonic frequencies. This progression has also seen the addition of forged rods and pistons initially in forced induction engines and more recently in normally aspirated engines. Adding these additional forged components improves the engine’s rigidity and further reduces concern about crankshaft damage. With the advent of computer aided design and finite element analysis, manufacturers can now find and re-engineer weaker areas. Regardless of some of these improvements, certain engines, like the traditional V8, have a firing order prone to excessive harmonics by nature necessitating the use of this device. The flat plane V8, traditionally used in more exotic engines, does not suffer from the excessive harmonics and therefore may use a solid undampened device. Modern (roughly 1988+) DOHC, SOHC Flat 4, Flat 6, Flat 8, Flat Plane V8 have no need for this device. Over the years many of these engines use solid cast iron or aluminum crank pulley or audible NVH damper (reducing engine noise heard in the occupant compartment). Audible NVH has been the biggest factor in OE manufacturer decisions throughout the vehicle. In addition, the pulleys on these engines are mounted loosely with a location fit negating any potential to act as an engine protective damper.
The damper will be fitted at the front of the engine (opposite the clutch or transmission) just beyond the cover of the timing chain, gears, or belt, and behind the accessory drive pulley (which may carry one or more V, serpentine, or cogged belts.) In older vehicles the pulley and damper were separate units that were bolted together. In late model vehicles the two have been combined into one unit. Timing marks are almost always engraved for purposes of setting the ignition timing.
OE dampers are predominantly made using rubber as the bonding agent between the inner hub and the outer mass. Rubber is susceptible to operational and environmental factors. Rubber only has a finite ability to withstand operating temperatures plus any fluids that may find their way onto the damper. They are also susceptible to low temperatures which can make the rubber brittle. Any cracking of the elastomer(rubber) would be an immediate indicator of the need to replace the unit. OE dampers must be balanced, unless acting as an external balancer (Harmonic Balancer), as the quality of materials (usually cast or sintered iron) do not lend themselves to acceptable/perfect balance specifications straight from manufacturing. Most aftermarket dampers are rebuildable, excluding the fluid type. When used in racing (drag, circle track, road race, etc.) they require regular inspection to ensure their proper function. When used on street driven vehicles, the damper manufacturer can provide inspection and service intervals based on the particulars of the engine the damper is being used on.
This will depend on a number of factors from quality of engine materials used to engine balance to the type of crankshaft design the quality of engine tune and more. Engines have continually improved in nearly all aspects but most importantly in quality of materials used and their manufacture (also discussed in Engine design, materials & other factors above). These improvements range from forged crankshafts, pistons and rods to other rotational components. Engine balance has also improved significantly through more advanced balancing techniques and the higher quality engine components which make the balancing process easier. Many OE manufacturers have been achieving 0 gram balance across their production since the 1980s. Crankshaft design is also a factor as cross plane crankshafts can be the most susceptible to internal harmonic damage. Flat plane crankshafts, I format and H format engines do not exhibit these issues but can reach extreme output and RPM levels where a harmonic damper may be necessary. Last is the quality of the tune which can be one of the most significant factors due to all sorts of negatives associated with poor tunes from detonation to over-boosting. Other factors like piston pin offset, TDC dwell time and stroke length can be factors but are primarily limited to cross plane engines.
Both Frederick Henry Royce and Frederick W. Lanchester have strong claims to the invention of the vibration damper, with the latest research showing Rolls-Royce using a crankshaft slipper (friction) vibration damper on their 1906 30HP models; however, Royce had not submitted it for patent. Lanchester had developed a theoretical multi-plate viscous design in 1910 (patent 21,139, 12 September 1910). This design was adopted by the Daimler Company and employed on their six-cylinder engines for a number of years. Royce developed a viscous damper in 1912 that was then further developed and carried through to the B60 engine of the 1950s. [2]
A crankshaft is a mechanical component used in a piston engine to convert the reciprocating motion into rotational motion. The crankshaft is a rotating shaft containing one or more crankpins, that are driven by the pistons via the connecting rods.
A V6 engine is a six-cylinder piston engine where the cylinders share a common crankshaft and are arranged in a V configuration.
A V engine, sometimes called a Vee engine, is a common configuration for internal combustion engines. It consists of two cylinder banks—usually with the same number of cylinders in each bank—connected to a common crankshaft. These cylinder banks are arranged at an angle to each other, so that the banks form a "V" shape when viewed from the front of the engine.
A flat-four engine, also known as a horizontally opposed-four engine, is a four-cylinder piston engine with two banks of cylinders lying on opposite sides of a common crankshaft. The most common type of flat-four engine is the boxer-four engine, each pair of opposed pistons moves inwards and outwards at the same time.
The straight-eight engine or inline-eight engine is an eight-cylinder internal combustion engine with all eight cylinders mounted in a straight line along the crankcase. The type has been produced in side-valve, IOE, overhead-valve, sleeve-valve, and overhead-cam configurations.
A tuned mass damper (TMD), also known as a harmonic absorber or seismic damper, is a device mounted in structures to reduce mechanical vibrations, consisting of a mass mounted on one or more damped springs. Its oscillation frequency is tuned to be similar to the resonant frequency of the object it is mounted to, and reduces the object's maximum amplitude while weighing much less than it.
Torsional vibration is the angular vibration of an object - commonly a shaft - along its axis of rotation. Torsional vibration is often a concern in power transmission systems using rotating shafts or couplings, where it can cause failures if not controlled. A second effect of torsional vibrations applies to passenger cars. Torsional vibrations can lead to seat vibrations or noise at certain speeds. Both reduce the comfort.
Engine balance refers to how the inertial forces produced by moving parts in an internal combustion engine or steam engine are neutralised with counterweights and balance shafts, to prevent unpleasant and potentially damaging vibration. The strongest inertial forces occur at crankshaft speed and balance is mandatory, while forces at twice crankshaft speed can become significant in some cases.
The crossplane or cross-plane is a crankshaft design for piston engines with a 90° angle between the crank throws. The crossplane crankshaft is the most popular configuration used in V8 road cars.
Mechanical resonance is the tendency of a mechanical system to respond at greater amplitude when the frequency of its oscillations matches the system's natural frequency of vibration closer than it does other frequencies. It may cause violent swaying motions and potentially catastrophic failure in improperly constructed structures including bridges, buildings and airplanes. This is a phenomenon known as resonance disaster.
A propeller speed reduction unit is a gearbox or a belt and pulley device used to reduce the output revolutions per minute (rpm) from the higher input rpm of the powerplant. This allows the use of small displacement internal combustion engines to turn aircraft propellers within an efficient speed range.
Vibration isolation is the prevention of transmission of vibration from one component of a system to others parts of the same system, as in buildings or mechanical systems. Vibration is undesirable in many domains, primarily engineered systems and habitable spaces, and methods have been developed to prevent the transfer of vibration to such systems. Vibrations propagate via mechanical waves and certain mechanical linkages conduct vibrations more efficiently than others. Passive vibration isolation makes use of materials and mechanical linkages that absorb and damp these mechanical waves. Active vibration isolation involves sensors and actuators that produce disruptive interference that cancels-out incoming vibration.
Noise, vibration, and harshness (NVH), also known as noise and vibration (N&V), is the study and modification of the noise and vibration characteristics of vehicles, particularly cars and trucks. While noise and vibration can be readily measured, harshness is a subjective quality, and is measured either via jury evaluations, or with analytical tools that can provide results reflecting human subjective impressions. The latter tools belong to the field psychoacoustics.
A V8 engine is an eight-cylinder piston engine in which two banks of four cylinders share a common crankshaft and are arranged in a V configuration.
Vibration is a mechanical phenomenon whereby oscillations occur about an equilibrium point. Vibration may be deterministic if the oscillations can be characterised precisely, or random if the oscillations can only be analysed statistically.
Noise and vibration on maritime vessels are not the same but they have the same origin and come in many forms. The methods to handle the related problems are similar, to a certain level, where most shipboard noise problems are reduced by controlling vibration.
A crank sensor (CKP) is an electronic device used in an internal combustion engine, both petrol and diesel, to monitor the position or rotational speed of the crankshaft. This information is used by engine management systems to control the fuel injection or the ignition system timing and other engine parameters. Before electronic crank sensors were available, the distributor would have to be manually adjusted to a timing mark on petrol engines.
The Geislinger coupling is an all-metal coupling for rotating shafts. It is elastic in torsion, allowing it to absorb torsional vibration.
A centrifugal pendulum absorber is a type of tuned mass damper. It reduces the amplitude of a torsional vibration in drive trains that use a combustion engine.
A dual-mass flywheel is a rotating mechanical device that is used to provide continuous energy in systems where the energy source is not continuous, the same way as a conventional flywheel acts, but damping any violent variation of torque or revolutions that could cause an unwanted vibration. The vibration reduction is achieved by accumulating stored energy in the two flywheel half masses over a period of time but damped by arc springs, doing that at a rate that is compatible with the energy source, and then releasing that energy at a much higher rate over a relatively short time. A compact dual-mass flywheel often includes the whole clutch, including the pressure plate and the friction disc.