Balancing Cam Mechanism for Instantaneous Torque and Velocity Stabilization in Internal Combustion Engines: Simulation and Experimental Validation

Daniel Silva Cardoso, Paulo Oliveira Fael, Pedro Dinis Gaspar () and António Espírito-Santo
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Daniel Silva Cardoso: C-MAST—Center for Mechanical and Aerospace Science and Technologies, Calçada Fonte do Lameiro, 6201-001 Covilhã, Portugal
Paulo Oliveira Fael: C-MAST—Center for Mechanical and Aerospace Science and Technologies, Calçada Fonte do Lameiro, 6201-001 Covilhã, Portugal
Pedro Dinis Gaspar: C-MAST—Center for Mechanical and Aerospace Science and Technologies, Calçada Fonte do Lameiro, 6201-001 Covilhã, Portugal
António Espírito-Santo: IT-Institute of Telecommunications, Calçada Fonte do Lameiro, 6201-001 Covilhã, Portugal

Energies, 2025, vol. 18, issue 13, 1-28

Abstract: Torque and velocity fluctuations in internal combustion engines (ICEs), particularly during idle and low-speed operation, can reduce efficiency, increase vibration, and impose mechanical stress on coupled systems. This work presents the design, simulation, and experimental validation of a passive balancing cam mechanism developed to mitigate fluctuations in single-cylinder internal combustion engines (ICEs). The system consists of a cam and a spring-loaded follower that synchronizes with the engine cycle to store and release energy, generating a compensatory torque that stabilizes rotational speed. The mechanism was implemented on a single-cylinder Honda ® engine and evaluated through simulations and laboratory tests under idle conditions. Results demonstrate a reduction in torque ripple amplitude of approximately 54% and standard deviation of 50%, as well as a decrease in angular speed fluctuation amplitude of about 43% and standard deviation of 42%, resulting in significantly smoother engine behavior. These improvements also address longstanding limitations in traditional powertrains, which often rely on heavy flywheels or electronically controlled dampers to manage rotational irregularities. Such solutions increase system complexity, weight, and energy losses. In contrast, the proposed passive mechanism offers a simpler, more efficient alternative, requiring no external control or energy input. Its effectiveness in stabilizing engine output makes it especially suited for integration into hybrid electric systems, where consistent generator performance and low mechanical noise are critical for efficient battery charging and protection of sensitive electronic components.

Keywords: torque fluctuation; velocity variation; balancing cam mechanism; cam profile; spring preload; follower inertia; experimental validation (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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