Category Archives: Between the Wars

Lycoming O-1230 front

Lycoming O-1230 Flat-12 Aircraft Engine

By William Pearce

In the late 1920s, the Lycoming Manufacturing Corporation of Williamsport (Lycoming County), Pennsylvania entered the aircraft engine business. At the time, Lycoming was a major supplier of automobile engines to a variety of different manufacturers. Lycoming quickly found success with a reliable nine-cylinder radial of 215 hp (160 kW), the R-680. However, the company wanted to expand into the high-power aircraft engine field.

Lycoming O-1230 front

When built, the Lycoming O-1230 was twice as large as and three times more powerful than any other aircraft engine the company had built. Lycoming essentially achieved the hyper engine goals originally set for the O-1230, but other engine developments had made the engine obsolete by the time it would have entered production.

In 1932, Lycoming became aware of the Army Air Corps’ (AAC) program to develop a high-performance (hyper) engine that would produce one horsepower per cubic inch displacement and one horsepower per pound of weight. The AAC had contracted Continental Motors in 1932 to work with the Power Plant Branch at Wright Field, Ohio on developing a hyper engine. The engine type was set by the AAC as a 1,200 hp (895 kW), flat, liquid-cooled, 12-cylinder engine that utilized individual-cylinder construction. The flat, or horizontally-opposed, engine configuration was selected to enable the engine’s installation buried in an aircraft’s wings.

Lycoming saw an opportunity to quickly establish itself as a high-power aircraft engine manufacturer by creating an engine that would satisfy the AAC’s hyper engine requirements. On its own initiative, Lycoming began development of its own hyper engine. The AAC encouraged Lycoming’s involvement and provided developmental support, but the AAC did not initially provide financial support. Lycoming started serious developmental work on the new engine in 1933. Various single-cylinder test engines were built and tested in 1934. In 1935, the AAC became more interested in the engine and began supporting Lycoming’s efforts. Single-cylinder testing yielded positive results, with the engine passing a 50-hour test in May 1936. That same year, the AAC contracted Lycoming to build a complete engine. Lycoming had spent $500,000 of its own money and had finalized the design of its engine, which was designated O-1230 (also as XO-1230). Construction of the first O-1230 was completed in 1937, and the engine was ready for endurance testing in December of that year.

Lycoming O-1230 side

Intended for installation buried in an aircraft’s wing, the O-1230’s height was kept to a minimum. The long nose case would aid in streamlined wing installations. Note that the supercharger’s diameter was slightly in excess of the engine’s height.

The Lycoming O-1230 hyper engine had a two-piece aluminum crankcase that was split vertically. Six individual cylinders attached to each side of the crankcase. The cylinders were made of steel and were surrounded by a steel water jacket. Each cylinder had a hemispherical combustion chamber with one intake and one sodium-cooled exhaust valve. A cam box mounted to the top of each cylinder bank, and each cam box contained a single camshaft that was shaft-driven from the front of the engine.

A downdraft carburetor fed fuel into the single-speed, single-stage supercharger mounted at the rear of the engine. Lycoming had experimented with direct fuel injection on test cylinders, but it is unlikely that any O-1230 ever used fuel injection. The supercharger’s 10 in (254 mm) diameter impeller was driven at 6.55 times crankshaft speed. It provided air to the intake manifold that sat atop the engine. Individual runners provided air to each cylinder from the intake manifold. Exhaust was expelled out the lower side of the cylinders and collected in a common manifold for each cylinder bank. An extended nose case housed the .40 propeller gear reduction, with options for a .50 or .333 reduction. On the top of the O-1230, just behind the gear reduction, was the engine’s sole magneto. The magneto was connected to two distributors, each driven from the front of the camshaft drive.

Lycoming O-1230 Vultee XA-19A

The O-1230-powered Vultee XA-19A before it arrived at Wright Field. The scoop above the cowling brought air into the engine’s carburetor. Louvered panels allowed heat generated by the exhaust manifold to escape the cowling.

The O-1230 had a 5.25 in (133 mm) bore and a 4.75 in (121 mm) stroke. The engine’s total displacement was 1,234 cu in (20.2 L), and it had a 6.5 to 1 compression ratio. The O-1230 produced 1,200 hp (895 kW) at 3,400 rpm for takeoff, 1,000 hp (746 kW) at 3,100 rpm for normal operation, and 700 hp (522 kW) at 2,650 rpm for cruise operation. The engine had an overspeed limit of 3,720 rpm for diving operations. The O-1230 was 106.7 in (2.71 m) long, 44.1 in (1.12 m) wide, and 37.9 in (.96 m) tall. The engine weighed 1,325 lb (601 kg).

After completing a type test in March 1939, the O-1230 was rated at 1,000 hp (746 kW). Continued development pushed the engine’s rating up to 1,200 hp (895 kW). The O-1230 was installed in a Vultee YA-19 attack aircraft that had been modified as an engine testbed and redesignated XA-19A (38-555). Some sources list the designation as YA-19A, but “Y” was typically used for pre-production aircraft, while “X” was for experimental aircraft. The O-1230-powered XA-19A first flew on 22 May 1940, the flight originating at Vultee Field in Downey, California. The aircraft and engine combination were transferred to Wright Field, Ohio in June 1940 and then to Lycoming on 27 March 1941. By this time, the AAC had already moved away from the buried-engine-installation concept and was interested in more powerful engines.

Lycoming O-1230 Vultee XA-19A side

The XA-19A is seen with its Wright Field markings. The aircraft’s tail was modified to compensate for the larger and longer nose needed to house the O-1230. The radiator positioned under the engine added bulk to the O-1230’s installation. Note the large exhaust outlet.

While the O-1230’s power output was on par with many of its contemporaries, such as the Allison V-1710, the O-1230 did not offer the same development potential or reliability as other engines. The O-1230 was cancelled in favor of other projects, and the engine was subsequently removed from the XA-19A airframe. The XA-19A was transferred to Pratt & Whitney on 8 August 1941, where an R-1830 was subsequently installed, and the aircraft was redesignated XA-19C.

Lycoming was still interested in developing a high-power engine and used O-1230 components to create the 24-cylinder XH-2470. In some regards, the Lycoming XH-2470 was two O-1230 engines mounted to a common crankcase. Lycoming started initial design work on the engine as early as 1938. A single O-1230 survived and is on display at the New England Air Museum in Windsor Locks, Connecticut.

Lycoming O-1230 display

The restored O-1230 on display at the New England Air Museum. The engine’s electric starter is mounted vertically just in front of the supercharger. (Daniel Berek image via Flickr.com)

Sources:
Development of Aircraft Engines and Fuels by Robert Schlaifer and S. D. Heron (1950)
Aircraft Engines of the World 1941 by Paul Wilkinson (1941)
Jane’s All the World’s Aircraft 1942 by Leonard Bridgman (1942)
“The Evolution of Reciprocating Engines at Lycoming” by A. E. Light, AIAA: Evolution of Aircraft/Aerospace Structures and Materials Symposium (24–25 April 1985)
“Vultee Engine-Test Aircraft in World War II” by Jonathan Thompson, AAHS Journal Volume 39 Number 4 (Winter 1994)

Bristol Hydra front

Bristol Hydra 16-Cylinder Radial Aircraft Engine

By William Pearce

In 1930, the Bristol Aeroplane Company began to contemplate the future of aircraft engines. Their engine department was run by Roy Fedden, a prolific aircraft engine designer. At the time, Bristol was manufacturing its nine-cylinder, single-row Mercury radial engine that had an output of 510 hp (380 kW) and displaced 1,519 cu in (24.9 L). The Mercury engine was under continuous development to increase its output. However, to produce more power out of the same basic engine size, Fedden realized that a second cylinder row was needed.

Bristol Hydra front

The Bristol Hydra was an odd radial engine utilizing two inline rows of eight cylinders. The engine suffered from vibration issues due to a lack of crankshaft support. Note the dual overhead camshafts for each front and rear cylinder pair.

Fedden and Bristol evaluated at least 28 engine designs to determine the best path forward for a multi-row engine. At the same time, Fedden was investigating a switch to using sleeve valves, but their development at Bristol had just begun. The multi-row engine would continue to use poppet valves. At the end of 1931, a 16-cylinder, air-cooled engine design was selected for development. This engine was called the Double Octagon or Hydra.

The Bristol Hydra was designed by Frank Owner in 1932, and the project was overseen by Fedden. The radial engine was very unusual in that it had an even number of cylinders for each row. Nearly all four-stroke radial engines have an odd number of cylinders per row so that every other cylinder can fire as the crankshaft turns. In addition, the Hydra’s cylinder rows were not staggered—the first and second rows were directly in line with each other. The “Double Octagon” name represented the engine’s configuration, in which the eight cylinders on each of the engine’s two rows formed an octagon. The name “Hydra” was given to the engine because of its numerous “heads” (cylinders).

Bristol Hydra side drawing Perkins

A sectional view of the Hydra created by Brian Perkins and based on a drawing found in the Bristol archives. The numbers in the drawing relate to the number of gear teeth. Note the unsupported crankshaft center section that joined the front and rear crankshaft sections. (Brain Perkins drawing via the Aircraft Engine Historical Society)

Unlike a traditional radial engine, the Hydra’s design resembled four V-4 engines mounted to a common crankcase and using a common crankshaft. In fact, a V-4 test engine was built to refine the Hydra’s cylinder and valve train design before a complete engine was built. The V-4 cylinder sections were mounted at 90-degree intervals around the crankcase, and their cylinders had a 45-degree bank angle. This configuration spaced all cylinder banks at 45-degree intervals. The V-4 cylinder sections had their exhaust ports located on the outer sides and their intake ports positioned in the Vee of each V-4 cylinder section. Two supercharger-fed intake manifolds delivered air to the Vee of each V-4 cylinder section, with each manifold servicing one front and rear cylinder. The engine’s supercharger turned at over four times crankshaft speed.

The Hydra used an aluminum cylinder that was machined all over with cooling fins. A steel barrel lined the inside of the cylinder. Each cylinder had one intake and one exhaust valve. Each front and rear cylinder formed a pair, and each cylinder pair had separate overhead camshafts that directly operated the intake and exhaust valves. At the rear of the cylinder pair, the exhaust camshaft was driven via beveled gears by a vertical shaft that was powered from the crankshaft by a gear set. A short cross shaft extended from the exhaust camshaft to power the intake camshaft. Each cylinder had two spark plugs.

Bristol Hydra 16-cylinder

Front and side view of the Hydra. Note the exhaust stacks protruding slightly above the cylinders.

The engine’s crankshaft was built-up from three pieces. The center piece joined the front and rear sections via four clamping bolts. The crankshaft only had two main bearings and no center support. Single-piece master connecting rods were used. A bevel gear reduction at the front of the engine reduced the propeller speed to .42 times that of the crankshaft. The relatively high-level of gear reduction was needed because of the engine’s high operating speed.

The Hydra had a 5.0 in (127 mm) bore and stroke. The engine’s total displacement was 1,571 cu in (25.7 L). The Hydra had a 6 to 1 compression ratio and produced 870 hp (649 kW) on 75 octane fuel. On 87 octane fuel, the engine reportedly produced 1,020 hp (761 kW). The power outputs were achieved at 3,620 rpm, a very high speed for a radial engine. The engine was 46.5 in (1.18 m) in diameter, 57 in (1.45 m) long, and weighed approximately 1,500 lb (680 kg). With its unusual cylinder configuration, the Hydra had the following cylinder firing order: 1F, 2F, 7R, 4F, 1R, 6F, 3R, 8F, 5R, 6R, 3F, 8R, 5F, 2R, 7F, and 4R.

Bristol Hydra Hawker Harrier

Hydra engine installed in the sole Hawker Harrier. Note the baffling on the engine. The four-blade test club propeller was fitted for ground runs.

The Hydra V-4 test engine underwent runs in mid-1932 and eventually produced around 190 hp (142 kW) with no cooling issues. A complete 16-cylinder Hydra was first run in 1933. Later that year, the engine was installed in the sole Hawker Harrier biplane bomber prototype, J8325. The engine’s configuration made installation very easy, and the intake Vees were baffled to improve cooling airflow.

The Hydra-powered Harrier encountered some oil leaks and ignition issues, but the main trouble was with excessive engine vibration. The lack of a center main bearing on the crankshaft caused the vibration issues, which could be quite severe at certain RPMs. The short stroke of the engine combined with a short crankshaft gave the designers the false hope that the center main bearing would not be needed. A redesign of the engine was required to cure the vibration issues.

Bristol Hydra Hawker Harrier side

The Hydra-powered Harrier completely cowled and with its three-blade flight propeller. The aircraft was flown in this configuration during 1933, but engine vibration issues at critical RPMs limited the testing.

By 1934, the Mercury was approaching the 800 hp (597 kW) level, and the new nine-cylinder, 1,753 cu in (28.7 L) Pegasus was giving every indication that 900 hp (671 kW) was just around the corner. In addition, the sleeve valve, 1,519 cu in (24.9 L) Perseus engine had proved reliable and was producing around 700 hp (522 kW), and more ambitious sleeve valve engines were being designed. Rather than proceed with the Hydra and its double-octagon configuration, Bristol chose to develop its existing production engines and also focus on new sleeve valve engines.

The Hydra engine project was funded entirely by Bristol, although Fedden tried to get Air Ministry support. Only two Bristol Hydra engines were built; remarkably, both are reported to still exist. One is housed at the Sir Roy Fedden Heritage Centre, Bristol Branch of the Rolls-Royce Heritage Trust, in Bristol, United Kingdom. The other engine is stored at the Royal Air Force Museum London, located on the old Hendon Aerodrome.

Bristol Hydra display

A preserved Bristol Hydra engine held by the Bristol Branch of the Rolls-Royce Heritage Trust. Note the extensive finning on the aluminum cylinders. (Brain Perkins image via the Aircraft Engine Historical Society)

Sources:
Fedden – the life of Sir Roy Fedden by Bill Gunston (1998)
British Piston Aero-Engines and their Aircraft by Alec Lumsden (2003)
An Account of Partnership – Industry, Government and the Aero Engine by George Bulman and edited by Mike Neale (2002)
“My Wife Calls it an Obsession!!!! Part 2: Bristol Hydra” by Brian Perkins Torque Meter Volume 4, Number 2 (Spring 2005)
“The Future of the Air-Cooled Engine” Flight (25 February 1937)
http://www.enginehistory.org/ModelEngines/Perkins/Hydra/bristol_hydra.shtml

Fairey Fox II P12 engine run

Fairey P.12 Prince Aircraft Engine

By William Pearce

Charles Richard Fairey founded the Fairey Aviation Company (FAC) in 1915. Fairey was at Cowes, Isle of Wight, United Kingdom in September 1923 to witness a practice session for the Schneider Trophy seaplane race over the Solent. What he saw both impressed and disappointed him.

Curtiss D-12 Fairey Felix

The Curtiss D-12 so impressed Richard Fairey that he went to the United States and acquired a license to produce the engine. Named the Fairey Felix, the engine was actually never produced, but 50 D-12 engines were imported.

Fairey was impressed by the Curtiss CR-3 racers, each with its compact 450 hp (336 kW) Curtiss D-12 engine turning a Curtiss-Reed metal propeller. When the race was run, the two CR-3 aircraft from the United States (US) proved to be 20 mph (32 km/h) faster than the British Supermarine Sea Lion racer. The Sea Lion was powered by a 550 hp (410 kW) Napier Lion W-12 engine that turned a wooden propeller. The two CR-3s finished the race averaging 177.266 mph (285.282 km/h) and 173.347 mph (278.975 km/h), while the Sea Lion averaged 157.065 mph (252.772 km/h). Fairey was disappointed that the British Air Ministry was not pushing its aircraft industry to make the same technological strides that were taking place in the US. Fairey was already frustrated by the constraints the Air Ministry placed on their specifications for new aircraft. With the world-beating performance of the Curtiss CR-3 aircraft fresh in his mind, Fairey resolved that if the Air Ministry would not push technology, he would.

Fairey went first to the Air Ministry seeking support for his new aircraft and was promptly turned down. Fairey then traveled to the US where, at great expense, he obtained manufacturing licenses for the Curtiss D-12 engine and Curtiss-Reed propeller. This agreement included some 50 D-12 engines to be used while FAC tooled up to manufacture their version, which was called the Felix. Fairey was so enthusiastic about the D-12, that he somehow smuggled an engine into his stateroom for his return sea voyage to Britain.

Fairey Fox bomber D-12 Felix

The Fairey Fox I light bomber was powered by the D-12/Felix engine. The aircraft was a private venture, and its performance surpassed other bombers and most fighters then in service. The British Air Ministry did not appreciate Fairey’s non-conformist attitude or the aircraft’s foreign power plant.

The D-12/Felix was a normally aspirated, liquid cooled, 60 degree, V-12 engine. The engine had a 4.5 in (114 mm) bore and a 6.0 in (160 mm) stroke. The D-12/Felix’s total displacement was 1,145 cu in (18.8 L), and it produced 435 hp (324 kW) at 2,300 rpm. The engine had four valves per cylinder that were operated by dual overhead camshafts.

With the engine situation under control, Fairey had his design department drew up plans for a new aircraft to be powered by the D-12/Felix. What came off the drawing board was the Fairey Fox I light bomber. Piloted by Norman Macmillan, the Fox I was flown for the first time on 3 January 1925. The Fox I had a top speed of 156 mph (251 km/h), some 50 mph (80 km/h) faster than comparable bombers then in service and also faster than most frontline fighters. Although it was built as a private venture, the Air Ministry was forced to buy a few Fox I bombers because of the aircraft’s unparalleled performance. The Air Ministry was not pleased with the situation and was downright appalled that the aircraft was powered by a US engine. Moreover, they did not want another aircraft engine manufacturer in Britain.

The Air Ministry tasked Rolls-Royce to develop an engine superior to the D-12. This new engine was developed as the Rolls-Royce Kestrel (type F) and was a stepping stone to the Merlin. The whole situation did nothing to improve the relationship between Fairey and the Air Ministry. However, had Fairey not forced the D-12 upon the Air Ministry, it is entirely possible that there may not have been a Merlin engine ready for the Battle of Britain in 1940.

Fairey P12 induction side

British patent 402,602 outlined how passageways cast into an engine’s crankcase could bring induction air into the cylinders. The patent also states how special oil lines (h) could traverse the passageway. This would help cool the oil and heat the incoming air/fuel mixture (which is not a good idea when higher levels of supercharging are applied to the engine).

The small order of Fox aircraft meant that the Fairey Felix engine never went into production. Only 28 Fox I aircraft were built, and a number were either built with or re-engined with Kestrel engines. FAC also built the D-12-powered Firefly I fighter, which first flew on 9 November 1925 and had a 185 mph (298 km/h) top speed. No orders were placed for the Firefly I.

Failing to enter the aircraft engine business on his first attempt did not stop Fairey from trying again. In 1931, FAC had hired Captain Archibald Graham Forsyth as chief engine designer. Forsyth had previously worked with Napier and Rolls-Royce while he was with the Air Ministry. Forsyth went to work designing a new aircraft engine. During this same period, Rolls-Royce started work on their PV-12 engine, which would become the Merlin.

Forsyth developed a liquid-cooled, 60 degree, V-12 engine known as the P.12. The upper crankcase and cylinder banks of the P.12 were cast together. Each detachable cylinder head housed four valves per cylinder. Reportedly, the P.12 used a dual overhead camshaft valve train similar to that used on the D-12/Felix. Cast into the Vee of the engine was the intake manifold and the runners, which branched off from the manifold. The intake runners aligned with passages cast integral with the cylinder head that led to the cylinders. The integral intake manifolds increased the engine’s rigidity, eliminated many pipe connections, and gave the engine a much cleaner appearance.

Fairey P12 engine section

A drawing from British patent 406,118 illustrates the induction passageways (d, e, and f) cast integral with the engine’s crankcase and head. The drawing also shows the water circulation from the crankcase to up around the cylinders and into the cylinder head. Although the valve arrangement is not specified, it is easy to see how four valves per cylinder with dual overhead camshafts could be accommodated.

The Fairey P.12 had a 5.25 in (133 mm) bore and a 6.0 in (152 mm) stroke. The engine’s total displacement was 1,559 cu in (25.5 L). Two versions of the P.12 were designed that varied in their amount of supercharging. The lightly-supercharged (some sources say unsupercharged) P.12 Prince produced 650–710 hp (485–529 kW) at 2,500 rpm. The moderately-supercharged P.12 Super Prince (or Prince II) produced 720–835 hp (537–623 kW) at 2,500 rpm. The P.12 engine weighed around 875 lb (397 kg).

The P.12 engine was first run in 1933. By 1934, three engines had been built and had run a total of 550 hours. One engine had run non-stop for 10 hours at 520 hp (388 kW) and had made three one-hour runs at 700 hp (522 kW). In late 1934, a P.12 Prince engine was installed in a Belgium-built Fox II (A.F.6022) aircraft (A.F.6022). The Prince-powered aircraft made its first flight on 7 March 1935. Ultimately, P.12 engines were run around 1,000 hours and had a final rating of 750 hp (559 kW) for normal output and 900 hp (671 kW) for maximum output.

Fairey Fox II P12 engine run

The Fairey Fox II was used as a testbed for the P.12 Prince engine. Unfortunately, little information has been found regarding the engine or its testing. Note the two exhaust stacks for each cylinder. The arrangement was similar to that used on the D-12/Felix engine.

In 1933, the Air Ministry issued specification P27/32 for a new light bomber. Marcel Lobelle, chief designer at FAC, drew up a number of designs, including one powered by two P.12 Prince engines. However, the Air Ministry wanted a single-engine aircraft. Lobelle altered the twin-engine design into what was basically a P.12-powered early design of the Fairley Battle. The Air Ministry made it clear to FAC that it would not consider any P.12-powered aircraft, because FAC was not a recognized engine manufacturer, and the Air Ministry did not want any other firms entering the aircraft engine field. Consequently, the FAC design for the P27/33 specification was switched to A Rolls-Royce Merlin I engine in 1934. This design was contracted as the Fairey Battle. The Battle was first flown on 10 March 1936 by Christopher Staniland, but an order for 155 aircraft (under specification P.23/35) had already been placed in May 1935. The Battle was the first production aircraft powered by the Merlin engine. With no support from the Air Ministry, the P.12 Prince faded into history.

Encouraged by the early bench tests of the P.12, Forsyth designed a more powerful 16-cylinder engine in January 1935 that was designated P.16. Initially, the P.16 design was basically a P.12 with four additional cylinders to make a V-16 engine. The P.16 used the same bore and stroke as the P.12 but displaced 2,078 cu in (34.1 L). Some sources state the P.16 was guaranteed to produce 900 hp (671 kW) at 12,000 ft (3,658 m) with a weight of only 1,150 lb (522 kg). The 900 hp (671 kW) output seems low, especially when compared to the anticipated performance of the Super Prince.

Fairey P27-32

FAC’s proposal to specification P27/32 included two twin-engine aircraft powered by P.12 Prince engines. The Air Ministry wanted a single-engine aircraft and would not consider anything powered by FAC engines. The specification and design eventually became the Fairey Battle.

Numerous sources suggest the P.16’s configuration was changed over concerns regarding the engine’s length combined with excessive torsional vibrations and stress of the V-16’s long crankshaft. The new, revised layout of the P.16 was an H-16 engine with two crankshafts, four banks of four cylinders, and an output of 1,540 hp (1,148 kW). This power level seems more reasonable than the 900 hp (671 kW) listed previously, but some sources give the 1,540 hp (1,148 kW) figure as an early power rating of a different engine (the P.24 Monarch). On occasion, the H-16 engine has been referred to as the P.16 Queen, but “Queen” was an early name for the P.24 Monarch. It may be that the H-16 engine never existed and has been mistaken for the P.24 over the years.

A third P.16 layout is described by other sources, which details the engine as a U-16 with two straight-eight engines mounted in parallel and geared to a common propeller shaft. FAC and Forsyth applied for a patent on 31 January 1936 (British patent 469,615) for such an engine configuration, but that date is after FAC moved away from the P.16, and the drawings depict a 12-cylinder engine. Both the H-16 and U-16 configurations would result in a much heavier engine of around 1,500 lb (680 kg).

Rather than proceed with a 16-cylinder engine, a new design had been started by October 1935. In fact, there is little evidence from primary sources that indicates a P.16 engine or an H-16 configuration were ever seriously considered. The new engine would keep the bore and stroke of the P.12 and use an H layout with four banks of six cylinders for a total of 24 cylinders. The H-24 engine design was called the Fairey P.24 Monarch.

Fairey U engine

Some sources state the P.16 engine was really two inline-eight engines coupled together as a U-16. While no drawings of a U-16 have been found, FAC and Forsyth did take out a British patent (no. 469,615) for a similar engine. This U-12 design was probably more of a stepping stone to the P.24 than a development of the P.16. Note the barrel (c) drawn between the cylinder banks.

Sources:
Fairey Aircraft since 1915 by H. A. Taylor (1988)
British Piston Aero-Engines and their Aircraft by Alec Lumsden (2003)
World Encyclopedia of Aero Engines by Bill Gunston (2006)
Memorandum Report on Fairey P-24 (Monarch) Engine by B. Beaman, F. L. Prescott, E. A. Wolfe, and Opie Chenoweth (22 August 1941)
“Improvements in or relating to the Induction and Lubrication Systems of an Internal Combustion Engine” British patent 402,602 by Fairey Aviation Company and Archibald Graham Forsyth (granted 7 December 1933)
“Improvements in or relating to the Cylinder Block and Crank Case of an Internal Combustion Engine” British patent 406,118 by Fairey Aviation Company and Archibald Graham Forsyth (granted 22 February 1934)
“Improvements in or relating to Power Plants for Aircraft” British patent 469,615 by Fairey Aviation Company and Archibald Graham Forsyth (granted 29 July 1937)
“Fairey Battle Database” by W. A Harrison Aeroplane (June 2016)

daimler-benz-db602-zeppelin-museum

Daimler-Benz DB 602 (LOF-6) V-16 Diesel Airship Engine

By William Pearce

Around 1930, Daimler-Benz* developed the F-2 engine, initially intended for aviation use. The F-2 was a 60 degree, supercharged, V-12 engine with individual cylinders and overhead camshafts. The engine had a 6.50 in (165 mm) bore and an 8.27 in (210 mm) stroke. The F-2’s total displacement was 3,288 cu in (53.88 L), and it had a compression ratio of 6.0 to 1. The engine produced 800 hp (597 kW) at 1,500 rpm and 1,000 hp (746 kW) at 1,700 rpm. The engine was available with either direct drive or a .51 gear reduction, and weighed around 1,725 lb (782 kg). It is unlikely that the Daimler-Benz F-2 powered any aircraft, but it was used in a few speed boats.

The Daimler-Benz OF-2 diesel engine was very similar to the spark ignition F-2. Note the dual overhead camshafts in the Elektron housing above the individual cylinders. This was one of the OF-2’s features that was not incorporated into the LOF-6.

The Daimler-Benz OF-2 diesel engine was very similar to the spark ignition F-2. Note the dual overhead camshafts in the Elektron housing above the individual cylinders. This was one of the OF-2’s features that was not incorporated into the LOF-6.

In the early 1930s, Daimler-Benz used the F-2 to develop a diesel engine for airships. This diesel engine was designated OF-2 (O standing for Ölmotor, or oil engine), and it maintained the same basic V-12 configuration as the F-2. The individual cylinders were mounted on an Elektron (magnesium alloy) crankcase. Each cylinder had four valves that were actuated by dual overhead camshafts. The OF-2 had the same bore, stroke, and displacement as the F-2, but the OF-2’s compression ratio was increased to 15 to 1.

Fuel was injected into the cylinders at 1,330 psi (91.7 bar) via two, six-plunger injection pumps built by Bosch. The fuel was injected into a pre-combustion chamber located between the four valves in the cylinder head. This design had been used in automotive diesels built by Mercedes-Benz. Sources disagree on the gear reduction ratio, and it is possible that more than one ratio was offered. Listed ratios include .83, .67, and .58.

The Daimler-Benz OF-2 engine had a normal output of 700 hp (522 kW) at 1,675 rpm, a maximum output of 750 hp (559 kW) at 1,720 rpm, and it was capable of 800 hp (597 kW) at 1,790 rpm for very short periods of time. Fuel consumption at normal power was .392 lb/hp/hr (238 g/kW/hr). The engine was 74.0 in (1.88 m) long, 38.6 in (.98 m) wide, and 42.5 in (1.08 m) tall. The OF-2 weighed 2,061 lb (935 kg).

daimler-benz-lof-6-db602-diesel-rear

This view of a display-quality DB 602 engine shows the four Bosch fuel injection pumps at the rear of the engine. The individual valve covers for each cylinder can also be seen.

The OF-2 passed its type test in 1932. At the time, Germany was developing its latest line of airships, the LZ 129 Hindenburg and LZ 130 Graf Zeppelin II. These airships were larger than any previously built, and four OF-2 engines would not be able to provide sufficient power for either airship. As a result, Daimler-Benz began developing a new engine to power the airships in 1933. Daimler-Benz designated the new diesel engine LOF-6, but it was soon given the RLM (Reichsluftfahrtministerium or Germany Air Ministry) designation DB 602.

Designed by Arthur Berger, the Daimler-Benz DB 602 was built upon lessons learned from the OF-2, but it was a completely new engine. The simplest way to build a more powerful engine based on the OF-2 design was by adding two additional cylinders to each cylinder bank, which made the DB 602 a V-16 engine. The two banks of eight cylinders were positioned at 50 degrees. The 50 degree angle was selected over the 45 degree angle typically used for a V-16 engine. This gave the DB 602 an uneven firing order which helped avoid periodic vibrations.

The individual steel cylinders were mounted to the aluminum alloy crankcase. About a third of the cylinder was above the crankcase, and the remaining two-thirds protruded into the crankcase. This arrangement helped eliminate lateral movement of the cylinders and decreased vibrations. The crankcase was made of two pieces and split horizontally through the crankshaft plane. The lower part of the crankcase was finned to increase its rigidity and help cool the engine oil.

Daimler-Benz LOF-6 DB602 V-16 diesel engine

Originally called the LOF-6, the Daimler-Benz DB 602 was a large 16-cylinder diesel engine built to power the largest German airships. Note the three-pointed star emblems on the front valve covers. Propeller gear reduction was achieved through bevel planetary gears.

A single camshaft was located in the Vee of the engine. The camshaft had two sets of intake and exhaust lobes per cylinder. One set was for normal operation, and the other set was for running the engine in reverse. The fore and aft movement of the camshaft to engage and disengage reverse operation was pneumatically controlled. Separate pushrods for the intake and exhaust valves rode on the camshaft and acted on duplex rocker arms that actuated the valves. Each cylinder had two intake and two exhaust valves. Four Bosch fuel injection pumps were located at the rear of the engine and were geared to the camshaft. Each injection pump provided fuel at 1,600 psi (110.3 bar) to four cylinders. Fuel was injected into the center of the pre-combustion chamber, which was situated between the four valves. For slow idle (as low as 300 rpm), fuel was cut from one cylinder bank.

The DB 602 engine was not supercharged and had a .50 propeller gear reduction that used bevel planetary gears. The engine used fork-and-blade connecting rods that rode on roller bearings fitted to the crankshaft. The camshaft also used roller bearings, but the crankshaft was supported by plain bearings. Two water pumps were driven by a cross shaft at the rear of the engine. Each pump provided cooling water to one cylinder bank. The engine’s compression ratio was 16.0 to 1, and it was started with compressed air.

The DB 602 had a 6.89 in (175 mm) bore and a 9.06 in (230 mm) stroke, both larger than those of the OF-2. The engine displaced 5,401 cu in (88.51 L). Its maximum continuous output was 900 hp (671 kW) at 1,480 rpm, and it could produce 1,320 hp (984 kW) at 1,650 rpm for 5 minutes. The DB 602 was 105.9 in (2.69 m) long, 40.0 in (1.02 m) wide, and 53.0 in (1.35 m) tall. The engine weighed 4,409 lb (2,000 kg). Fuel consumption at cruising power was 0.37 lb/hp/hr (225 g/kW/hr).

lz-129-hindenburg

The ill-fated LZ 129 Hindenburg on a flight in 1936. The airship used four DB 602 engines housed in separate cars in a pusher configuration. Note the Olympic rings painted on the airship to celebrate the summer games that were held in Berlin.

Development of the DB 602 progressed well, and it completed two non-stop 150-hour endurance test runs. The runs proved the engine could operate for long periods at 900 hp (671 kW). Four engines were installed in both the LZ 129 Hindenburg and the LZ 130 Graf Zeppelin II. Each engine powered a two-stage compressor. Each compressor filled a 3,051 cu in (50 L) air tank to 850 psi (59 bar) that was used to start the engine and to manipulate the camshaft for engine reversing.

Plans for a water vapor recovery system that used the engines’ exhaust were never implemented, because the airships used hydrogen instead of the more expensive helium. The recovery system would have condensed vapor into water, and the collected water would have been used as ballast to help maintain the airship’s weight and enable the retention of helium. Without the system in place, expensive helium would have been vented to compensate for the airship steadily getting lighter as diesel fuel was consumed. With the United States unwilling to provide helium because of Germany’s aggression, the airships used inexpensive and volatile hydrogen, as it was readily available. The Hindenburg was launched on 4 March 1936, and the Graf Zeppelin II was launched on 14 September 1938.

Engines for the Hindenburg were mounted in a pusher configuration. In April 1936, the Hindenburg’s DB 602 engines experienced some mechanical issues on its first commercial passenger flight, which was to Rio de Janeiro, Brazil. The engines were rebuilt following the airship’s return to Germany, and no further issues were encountered. The Hindenburg tragically and famously burst into flames on 6 May 1937 while landing at Lakehurst, New Jersey.

daimler-benz-db602-musee-de-l-air-et-de-l-espace

Front view of the DB 602 engine in the Musée de l’Air et de l’Espace, in Le Bourget, France. Above the engine are the cooling water outlet pipes. In the Vee of the engine is the induction manifold, and the pushrod tubes for the front cylinders can be seen. Note the finning on the bottom half of the crankcase. (Stephen Shakland image via flickr.com)

The Graf Zeppelin II was still being built when the Hindenburg disaster occurred. Design changes were made to the Graf Zeppelin II that included mounting the DB 602 engines in a tractor configuration. The inability of Germany to obtain helium, the start of World War II, and the end of the airship era meant the Graf Zeppelin II would not be used for commercial travel. The airship was broken up in April 1940.

The DB 602 engine proved to be an outstanding and reliable power plant. However, its capabilities will forever be overshadowed by the Hindenburg disaster. Two DB 602 engines still exist and are on display; one is in the Zeppelin Museum in Friedrichshafen, Germany, and the other is in the Musée de l’Air et de l’Espace, in Le Bourget, France. Although the DB 602 was not used on a wide scale, it did serve as the basis for the Mercedes-Benz 500 series marine engines that powered a variety of fast attack boats (Schnellboot) during World War II.

*Daimler-Benz was formed in 1926 with the merger of Daimler Motoren Gesellschaft and Benz & Cie. Prior to their merger, both companies produced aircraft engines under the respective names Mercedes and Benz. After the merger, the Daimler-Benz name was used mostly for aircraft engines, and the Mercedes-Benz name was used mostly for automobiles. However, both names were occasionally applied to aircraft engines in the 1930s.

daimler-benz-db602-zeppelin-museum

Rear view of the DB 602 engine on display in the Zeppelin Museum in Friedrichshafen, Germany. A water pump on each side of the engine provided cooling water to a bank of cylinders. (Stahlkocher image via Wikimedia Commons)

Sources:
Aircraft Diesels by Paul H Wilkinson (1940)
Aerosphere 1939 by Glenn D. Angle (1940)
Diesel Engines by B. J. von Bongart (1938)
High Speed Diesel Engines by Arthur W. Judge (1941)
Diesel Aviation Engines by Paul H Wilkinson (1942)
“The Hindenburg’s New Diesels” Flight (26 March 1936)
“The L.Z.129’s Power Units” Flight (2 January 1936)
https://en.wikipedia.org/wiki/LZ_129_Hindenburg
https://en.wikipedia.org/wiki/LZ_130_Graf_Zeppelin_II

tips-1917-18-cylinder-rotary-engine

Tips Aero Motor Rotary Aircraft Engines

By William Pearce

From a very early age, Maurice A. Tips and his younger brother Earnest Oscar were interested in aviation. By 1908, the Belgian siblings had built their first aircraft: a canard-design, pusher biplane. The first engine installed in the aircraft proved underpowered and was replaced with a Gnome rotary. The engine was geared to two shafts, each driving a two-blade pusher propeller. Although the aircraft made some flights, its handling was unsatisfactory, and the design was not developed further. The aircraft did possess unique concepts, a theme continued in Maurice’s subsequent designs.

tips-1908-biplane

Rear view of Maurice and Earnest Oscar Tips’ 1908 biplane pusher. The aircraft was unable to fly with its original Pipe V-8 engine, but the lighter Gnome rotary enabled the aircraft to takeoff. Note the central gearbox that provided power to the shafts that turned the propellers via right-angle drives.

After the 1908 aircraft, Maurice refocused his efforts on aircraft engines. By 1912, Maurice had designed a 25 hp (19 kW), seven-cylinder, “valveless,” rotary engine. The engine had a 2.76 in (70 mm) bore, a 4.33 in (110 mm) stroke, and a displacement of 181 cu in (3.0 L). Hollow “suction tubes” took the air/fuel mixture from the engine’s crankcase and delivered it to the cylinders. Each suction tube was geared to the engine’s fixed crankshaft. The suction tubes would spin at half the speed of the crankcase as it rotated. The top of the suction tube had two passageways. Each passageway would align with a common port near the top of the cylinder once every two revolutions of the crankcase. One passageway aligned to allow the air/fuel mixture to flow from the suction tube and into the cylinder. The second passageway aligned to allow the exhaust gases to flow from the cylinder out into the atmosphere.

Two larger versions of the seven-cylinder engine were planned. One had a 4.33 in (110 mm) bore, a 4.72 in (120 mm) stroke, a displacement of 487 cu in (8.0 L), and produced 50 hp (37 kW). The largest engine had a 4.41 in (112 mm) bore, a 5.12 in (130 mm) stroke, a displacement of 547 cu in (9.0 L), and produced 70 hp (52 kW). It does not appear that either of the larger engines were built.

tips-1912-7-cylinder-rotary-engine

Drawings of the 25 hp (19 kW) Tips engine of 1912. Air was drawn through the rotating suction tubes (5) which enable the intake port (14) and exhaust port (13) to align with the cylinder. The suction tubes were geared (9 and 10) to the stationary crankshaft (4).

Maurice worked to refine his “valveless” rotary engine throughout 1913 and 1914. The most obvious change was that the suction tube was moved to be parallel with the cylinder, rather than at an angle as seen in the 1912 engine. The newer engine design had an updated drive for the suction tubes, and the air/fuel mixture no longer passed through the crankcase; rather, it was delivered through a hollow extension of the crankshaft to a space under the suction tubes.

tips-engine-ad-1913

A 1912 advertisement for the Tips seven-cylinder engines. The ad is titled “The new rotary engines without valves,” and includes the more powerful 50 hp (37 kW) and 70 hp (52 kW) models.

A 25 hp (19 kW) Tips valveless rotary engine was installed in a monoplane built by Henri Gérard in 1914. However, it is not clear if the engine was the 1912 design or later. In addition, the results of the engine’s and aircraft’s performance have not been found. When World War I broke out, Maurice and Earnest Tips fled Belgium. Earnest made his way to Britain, where he worked with Charles Richard Fairey and helped start the Fairey Aviation Company in 1915. Earnest would return to Belgium in 1931 to start the Fairey subsidiary, Avions Fairey. He also produced the Tipsy series of light aircraft.

Maurice Tips traveled to the United States and continued to design aircraft engines. In 1917, The Tips Aero Motor Company was founded in Woonsocket, Rhode Island. That same year, Maurice applied for patents covering his new engine design, which incorporated many concepts from the earlier engines. The new Tips engine was an 18-cylinder, twin-row, rotary engine housed in a stationary frame. The new engine employed both water and air cooling. The cylinders were arranged in pairs, with one in the front row of the engine and the other in the rear row. The crankshaft had only one throw, and the pistons for both cylinders in a pair were at top dead center on their compression strokes at the same time. The engine’s compression ratio was 5.25 to 1. Each cylinder had one spark plug at the center of its combustion chamber. The spark plugs were fired by two magnetos mounted to the front of the engine and driven from the propeller shaft.

tips-1913-and-1914-rotary-engines

The 1913 (left) and 1914 (right) versions of the Tips rotary engine. The major changes were to the suction tube drive and rotary valves. The small tube (no. 14 on the 1913 engine and no. 40 on the 1914 engine) in the stationary crankshaft extension provided oil to the crankshaft and connecting rod.

Most rotary engines had a fixed crankshaft and a crankcase that rotated. This arrangement created much stress on the crankshaft and crankcase and also imposed severe gyroscopic effects on the aircraft. The Tips engine employed several unique characteristics to resolve the drawbacks of traditional rotary engines. The crankshaft of the Tips engine rotated and was geared to the propeller shaft. The propeller shaft was geared to the crankcase, which allowed it to rotate in the opposite direction from the crankshaft and propeller. The end result was that when the crankshaft was turning at 1,800 rpm, the propeller would turn at 1,080 rpm, and the crankcase would rotate at 60 rpm in the opposite direction. Rotary engines in which the crankshaft and crankcase rotate in opposite directions and at different speeds are often called bi-directional or differential rotary engines.

The propeller shaft of the Tips 18-cylinder engine was geared to the crankshaft at a .600 reduction; the crankshaft gear had 18 teeth, and the propeller shaft’s internal gear had 30 teeth. For crankcase rotation, the 17 teeth on the propeller shaft gear engaged 51 teeth on one side of a countershaft to give a .333 gear reduction. The other side of the countershaft had 11 teeth that meshed with a 66-tooth internal gear attached to the crankcase and resulted in a further .167 reduction. Having the propeller and crankshaft rotating in opposite directions not only eliminated the gyroscopic effect inherent to conventional rotary engines, but it also neutralized the gyroscopic effect created by the propeller attached to a fixed engine.

tips-1917-18-cylinder-rotary-engine

The 18-cylinder Tips engine of 1917 was far more complex than the earlier engines. Note the paired cylinders separated by the rotary valve (24). The propeller shaft (10) was geared to the crankshaft (7) via reduction gears (8 and 9). The crankcase was geared to the propeller shaft via a countershaft (16).

On the exterior of the cylinder castings were numerous cooling fins. In addition, internal passageways for water cooling were in the cylinder castings. Between each pair of cylinders were a series of air passageways to further augment cooling. The engine did not have a water pump; rather, thermosyphoning and the relatively slow rotation of the crankcase enabled the circulation of cooling water from the internal hot areas of the cylinders out toward the cooling fins on the exterior of the cylinders. The engine’s rotation also aided oil lubrication from the pressure-fed crankshaft to the rest of the engine. The oil pump and carburetor were located on the stationary frame at the rear of the engine.

A flange was positioned on the crankshaft, between the connecting rods of the cylinder pair. Mounted on the flange via ball bearings was an eccentric gear with 124 teeth on its outer edge. Attached (but not fixed) to the crankcase was a master valve gear that had 128 teeth on its inner edge. The gears meshing with an eccentric action resulted in the master valve gear turning four teeth per revolution of the crankshaft. On the outer edge of the master valve gear was a bevel gear with 128 teeth. These teeth engaged a 16-tooth pinion attached to a rotary valve positioned between each cylinder pair. The four teeth per revolution of the master valve gear acting on the 16-tooth rotary valve resulted in the rotary valve turning at a quarter engine speed. Each hollow rotary valve had two intake ports and two exhaust ports.

Air was drawn in through a carburetor at the rear of the engine. The air/fuel mixture flowed through a manifold bolted to the cylinder casting and into a passageway that led to a chamber around the lower part of the rotary valve. Holes in the valve allowed the air to flow up through its hollow middle and into the cylinder when the intake ports aligned. As the valve rotated, the exhaust ports would align with the cylinder, allowing the gases to escape out the top of the valve head and into the atmosphere. Passageways in the lower part of the rotary valve head brought in cooling water from the cylinder’s water jacket. Water flowed up through the rotary valve and back into the cylinder’s water jacket. The rotary valve was lubricated by graphite pads and held in place by a spiral spring and retaining cap around its upper surface.

tips-1917-18-cylinder-valves-and-gear

On the left is the rotary valve shown with the intake ports aligned (Fig 3). The air/fuel mixture entered the valve through ports in its lower end (27a). On the right is the valve with the exhaust ports aligned (Fig 5). Fig 4 shows a cross section of the rotary valve with intake ports (28), exhaust ports (29), and passageways for the flow of cooling water (30). Fig 8 shows the valve gear drive. The crankshaft (7) turned an eccentric gear (44) that meshed (42 and 41) with a gear mounted to the crankcase. The result is that a bevel gear (27) engaged a gear screwed to the bottom of the rotary valve (26 on Fig 3) and turned the valve once for every four revolutions of the crankshaft.

The 18-cylinder Tips engine had a 4.5 in (114 mm) bore and a 6.0 in (152 mm) stroke. The engine displaced 1,718 cu in (28.1 L) and produced 480 hp (358 kW) at 1,800 rpm. The Tips engine weighed 850 lb (386 kg). At speed, the engine consumed 22 gallons (83 L) of fuel and 3 gallons (11 L) of oil per hour. The oil consumption was particularly high, even for a rotary engine, but the Tips engine was larger and more powerful than other rotary engines.

In 1919, the engine was mentioned in a few publications. In 1920, Leo G. Benoit, Technical Manager at Tips Aero Motors, passed away. Benoit was said to be in charge of the engine’s design and construction. No further information regarding the engine and no images of the engine have been found. This lack of information could mean that the 480 hp (358 kW) Tips engine was never built. However, given the detailed description of the engine and that it was worked on from 1917 to at least 1920, the possibility certainly exists that the engine was built and tested.

Sometime before World War II, Maurice Tips returned to Belgium. He continued to design engines and applied for a patent on a rotary piston engine in 1938. This engine was not designed for aircraft use and bore no similarities to his early aircraft engines.

tips-1917-18-cylinder-rear

Rear view of the 480 hp (358 kW) Tips engine shows the extensive fining (22) that covered the engine. The fining and air passages (23) combined to turn the whole engine into a radiator to cool the water that flowed through the engine via thermosyphoning and centrifugal force.

Sources:
“Valveless Rotary Combustion Engine” US Patent 1,051,290 by Maurice Tips (granted 21 January 1913)
“Improvements in Rotary Combustion Engines” GB Patent 191307778 by Maurice Tips (application 15 April 1913)
“Improvements in or relating to Rotary Combustion Engines” GB Patent 191506821 by Maurice Tips (application 8 May 1914)
“Rotary Valve” US Patent 1,286,149 by Maurice A. Tips (granted 26 November 1918)
“Internal Combustion Engine” US Patent 1,306,035 by Maurice A. Tips (granted 10 June 1919)
“Valve-Operating Mechanism” US Patent 1,306,036 by Maurice A. Tips (granted 10 June 1919)
“Internal Combustion Engine” US Patent 2,203,449 by Maurice Tips (granted 4 June 1940)
“The Tips 480 H.P. Aero Motor” Aerial Age Weekly (17 March 1919)
Airplane Engine Encyclopedia by Glenn Angle (1921)
http://www.vieillestiges.be/fr/rememberbook/contents/42