Friction reduction in heavy-duty brake air compressor with innovative crank-connecting rod mechanism: Numerical and experimental study
Mechanics Based Design of Structures and Machines, cilt.54, sa.1, 2026 (SCI-Expanded, Scopus)
- Yayın Türü: Makale / Tam Makale
- Cilt numarası: 54 Sayı: 1
- Basım Tarihi: 2026
- Doi Numarası: 10.1080/15397734.2026.2688885
- Dergi Adı: Mechanics Based Design of Structures and Machines
- Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Compendex, INSPEC, DIALNET, Academic Search Ultimate (EBSCO), Engineering Source (EBSCO)
- Anahtar Kelimeler: Crank-connecting rod mechanisms, energy efficiency, piston secondary motion, piston-cylinder friction, reciprocating air compressor
- Gazi Üniversitesi Adresli: Evet
Özet
The most fundamental factor limiting energy efficiency in internal combustion engines and their auxiliary equipment is mechanical losses caused by friction. Particularly in systems with a crankshaft-connecting rod mechanism, the lateral forces resulting from the piston’s secondary motion account for approximately half of the total friction. In this study, an innovative “piston-free crankshaft-connecting rod mechanism” that eliminates lateral loads in heavy-duty vehicle brake air compressors has been developed. The designed mechanism was analyzed in comparison with the traditional system using analytical modeling, finite element analysis (FEA), and experimental methods. FEA results showed that friction losses at the piston-cylinder interface were reduced by 80–85%, corresponding to a 4–6% improvement in total mechanical losses. In experimental tests conducted within a speed range of 600–1050 rpm and an operating pressure range of 1–3 bar, it was determined that the new mechanism consumed an average of 3.23% less power compared to the traditional system. Additionally, an increase of 2.2% in air flow rate was recorded due to improved kinematic stability and sealing. The findings demonstrate that the proposed mechanism offers a significant advantage over traditional and other alternative systems due to its direct integrability into the existing block structure, low cost, and high mechanical efficiency.