Part 4

The crankshaft was made from a solid block of relatively high carbon steel which, aside from its bulk and the major amount of machining required, presented no special problems. It was heat-treated to a machinable hardness before being worked on, but was not further tempered. The design was an orthodox straight pin and cheek combination and, as previously noted, there were no counterweights to complicate the machining or assembly. A sizable bearing was provided on each side of each crank of the shaft, which helped reduce the stiffness requirement.

Their only serious design consideration was to maintain the desired strength and still keep within weight limitations. A fundamental that every professional designer knows is that it is with this particular sort of part that weight gets out of control; even an additional 1/16 in., if added in a few places, can balloon the weight. With their usual foresight and planning, the Wrights carefully checked and recorded the weight of each part as it was finished, but even this does not quite explain how these two individuals, inexperienced in multicylinder engines--much less in extra-light construction--could, in two months, bring through an engine which was both operable and somewhat lighter than their specification.

In one matter it would seem that they were quite fortunate. The records are not complete, but with one exception there is no indication of any chronic or even occasional crankshaft failure. This would seem to show that it apparently never happened that any of their designs came out such that the frequency of a vibrating force of any magnitude occurred at the natural frequency of the shaft. Much later, when this type of vibration became understood, it was found virtually impossible, with power outputs of any magnitude, to design an undampened shaft, within the space and weight limitations existing in an ordinary engine, strong enough to withstand the stress generated when the frequency of the imposed vibration approximated the natural frequency of the shaft. The vibratory forces were mostly relatively small in their engines, so that forced vibration probably was not encountered, and the operating speed range of the engines was so limited that the natural frequency always fell outside this range.

The flywheel was about the least complex of any of their engine parts and required little studied consideration, although they did have to balance its weight against the magnitude of the explosion forces which would reach the power transmission chains, with their complete lack of rigidity, a problem about which they were particularly concerned. The flywheel was made of cast iron and was both keyed to and shrunk on the shaft.

Some doubt still exists about the exact method of lubricating the first engine. The unit presently in the airplane has a gear-type oil pump driven by the crankshaft through a worm gear and cross shaft, and the Appendix to the _Papers_ states that it was lubricated by a small pump; nevertheless Baker says, after careful research, that despite this evidence, it was not. Also, the drawings prepared by Christman (they were commenced under the supervision of Orville Wright) do not show the oil pump. In March 1905 Wilbur Wright wrote to Chanute, "However we have added oiling and feeding devices to the engine ..."; but this could possibly have referred to something other than an oil pump. But even if a pump was not included originally, its presence in the present engine is easily explained. Breakage of the crankcase casting caused the retirement of this engine, which was not rebuilt until much later, and the pattern for this part had no doubt long since been altered to incorporate a pump. It was therefore easier in rebuilding to include than to omit the pump, even though this required the addition of a cross shaft and worm gear combination. On later engines, when the pump was used, oil was carried to a small pipe, running along the inside of the case, which had four small drill holes so located as to throw the oil in a jet on the higher, thrust-loaded side of each cylinder. The rods had a sharp scupper on the outside of the big end so placed as also to throw the oil on this same thrust face. Some scuppers were drilled through to carry oil to the rod bearing and some were not.

The first engine was finished and assembled in February 1903 and given its first operating test on 22 February. The Wrights were quite pleased with its operation, and particularly with its smoothness. Their father, Bishop Wright, was the recorder of their satisfaction over its initial performance, but what he noted was probably the afterglow of the ineffable feeling of deep satisfaction that is the reward that comes to every maker of a new engine when it first comes to life and then throbs. They obtained 13 hp originally: later figures went as high as almost 16, but as different engine speeds were utilized it is rather difficult to settle on any single power figure. The most realistic is probably that given in the _Papers_ as having been attained later, after an accurate check had been made of the power required to turn a set of propellers at a given rpm. This came out at approximately 12 hp, the design goal having been 8. Following exactly the procedure that exists to this day, the engine went through an extended development period, and it was the end of September 1903 before it was taken, with the airplane, to Kitty Hawk where the historic flights, which have had such a profound effect on the lives of all men, were made on 17 December 1903.

The Engines With Which They Mastered The Art of Flying

Two more engines of this first general design were built but they differed somewhat from each other as well as from the original. Together with a third 8-cylinder engine these were begun right after the first of the year in 1904, shortly after the Wrights' return from Kitty Hawk. In planning the 8-cylinder engine they were again only being forehanded, but considerably so, in providing more power for increased airplane performance beyond that which might possibly be obtained from the 4-cylinder units. Progress with the 4-cylinder engines was such that they fairly quickly concluded that the 8-cylinder size would not be necessary, and it was abandoned before completion. Exactly how far it was carried is not known. The record contains only a single note covering the final scrapping of the parts that had been completed; and apparently there were no drawings, so that even its intended appearance is not known with any exactness. It was probably a 90° V-type using their original basic cylinder construction.

The changes carried through in the two 4-cylinder engines were not major. The water-cooled area of the cylinder barrel was increased by nearly ten percent but the head remained only partially cooled. In hindsight, this consistent avoidance of complete cylinder-head cooling presents the one most inexplicable of the more important design decisions they made, as it does not appear logical. In the original engine, where the factors of time and simplicity were of paramount importance, this made sense, but now they were contemplating considerably increased power requirements, knowing the effect of temperature on both the cylinder and the weight of cylinder charge, and knowing that valve failure was one of their most troublesome service problems. Nor does it seem that they could have been avoiding complete cylinder cooling through fear of the slightly increased complexity or the difficulty of keeping the water connections and joints tight, for they had faced a much more severe problem in their first engine, where their basic design required that three joints be kept tight with only two sets of threads, and had rather easily mastered it; so there must have been some much more major but not easily discernible factor which governed, for they still continued to use the poorly cooled head, even carrying it over to their next engine series. Very probably they did not know the effect on detonation of a high-temperature fuel-charge.

One of the new engines was intended for use in their future experimental flying and has become known as _No. 2._ It had a bore of 4-1/8 in., incorporated an oil pump, and at some time shortly after its construction a fuel pump was added. The fuel pump was undoubtedly intended to provide a metering system responsive to engine speed and possibly also to eliminate the small inherent variation in flow of the original gravity system.

This engine incorporated a cylinder compression release device not on the original. The exact reason or reasons for the application of the compression release have not been determined, although the record shows it to have been utilized for several different purposes under different operating conditions. Whatever the motivation for its initial application, it was apparently useful, as it was retained in one form or another in subsequent engine models up to the last 6-cylinder design. Essentially it was a manually controlled mechanism whereby all the exhaust valves could be held open as long as desired, thus preventing any normal charge intake or compression in the cylinder. Its one certain and common use was to facilitate starting, the open exhaust valves easing the task of turning the engine over by hand and making priming easy. In flight, its operation had the effect of completely shutting off the power. The propellers would then "windmill" and keep the engine revolving. One advantage stated for this method of operation was that when power was required and the control released, the engine would be at fairly high speed, so that full power was delivered immediately fuel reached the engine. It is also reported to have been used both in making normal landings and in emergencies, when an instant power shutdown was desired. Although it is not clear whether the fuel shutoff cock was intended to be manipulated when the compression release was used for any of these reasons, over the many years of its availability, undoubtedly at one time or another every conceivable combination of operating conditions of the various elements was tried. Because of the pumping power required with at least one valve open during every stroke, the windmilling speed of the engine was probably less than with any other method of completely stopping power output, but whether this difference was large enough to be noticeable, or was even considered, is doubtful.

Since a simple ignition switch was all that was required to stop the power output, regardless of whether a fuel-control valve or a spark-advance control was used, it must be concluded that the primary function of the compression release was to facilitate starting, and any other useful result was something obtained at no cost. The compression release was later generally abandoned, and until the advent of the mechanical starter during the 1920s, starting an engine by "pulling the propeller through" could be a difficult task. With the Wrights' demonstrated belief that frugality was a first principle of design, it is hardly conceivable that they would have accepted for any other reason the complication of the compression-release mechanism if a simple ignition switch would have sufficed.

The compression-release mechanism was kept relatively simple, considering what it was required to accomplish. A small non-revolving shaft was located directly under the rocker arm rollers that actuated the exhaust valves. Four slidable stops were placed on this shaft, each in the proper location, so that at one extreme of their travel they would be directly underneath the rocker roller and at the other extreme completely in the clear. They were positioned along the shaft by a spring forcing them in one direction against a shoulder integral with the shaft, and the shaft was slidable in its bearings, its position being determined by a manually controlled lever. When the lever was moved in one direction the spring pressure then imposed on the stops would cause each of them to move under the corresponding rocker roller as the exhaust valve opened, thus holding the exhaust valve in the open position. When the shaft was moved in the other direction the collar on the shaft would mechanically move the stop from underneath the roller, allowing the valve to return to normal operation.

If the 1903 engine is the most significant of all that the Wrights built and flew, then certainly the _No. 2_ unit was the most useful, for it was their sole power source during all their flying of 1904 and 1905 and, as they affirmed, it was during this period that they perfected the art, progressing from a short straightaway flight of 59 seconds to a flight controllable in all directions with the duration limited only by the fuel supply. It is to be greatly regretted that no complete log or record was kept of this engine.

The Wrights again exhibited their engineering mastery of a novel basic situation when, starting out to make flight a practical thing, they provided engine _No. 3_ to be used for experimental purposes. In so doing they initiated a system which continues to be fundamental in the art of providing serviceable aircraft engines to this day--one that is expensive and time consuming, but for which no substitute has yet been found. Their two objectives were: improvement in performance and improvement in reliability, and the engine was operated rather continuously from early 1904 until well into 1906. Unfortunately, again, no complete record exists of the many changes made and the ideas tested, although occasional notes are scattered through the diaries and notebooks.

In its present form--it is on exhibition at the Engineers Club in Dayton, Ohio--the _No. 3_ engine embodies one feature which became standard construction on all the Wright 4-cylinder models. This was the addition of a number of holes in a line part way around the circumference of the cylinder barrel so that they were uncovered by the piston at the end of its stroke toward the shaft, thus becoming exhaust ports (see Figure 9). This arrangement, although not entirely novel, was just beginning to come into use, and in its original form the ports exhausted into a separate chamber, which in turn was evacuated by means of a mechanically operated valve, so that two exhaust valves were needed per cylinder. Elimination of this chamber and the valve arrangement is typical of the Wrights' simplifying procedure, and it would seem that they were among the very first to use this form.[14]

[Footnote 14: Rankin Kennedy, _Flying Machines--Practice and Design_, 1909.]

The primary purpose of the scheme was to reduce, by this early release and consequent pressure and temperature drop, the temperature of the exhaust gases passing the exhaust valve, this valve being one of their main sources of mechanical trouble. It is probable that with the automatic intake valves being used there was also a slight effect in the direction of increasing the inlet charge, although with the small area of the ports and the short time of opening, the amount of this was certainly minor. With the original one-piece crankcase and cylinder jacket construction, the incorporation of this auxiliary porting was not easy, but this difficulty was overcome in the development engine by making different castings for the crankcase itself and for the cylinder jacket and separating them by several inches, so that room was provided between the two for the ports.

This engine demonstrated the most power of any of the flat 4s, eventually reaching an output of approximately 25 hp, which was even somewhat more than that developed by the slightly larger 4-1/8-in.-bore flight engine, with which 21 hp was not exceeded. Indicative of the development that had taken place, the performance of the _No. 3_ engine was twice the utilized output of the original engine of the same size, an increase that was accomplished in a period of less than three years.

The Wrights were only twice charged with having plagiarized others' work, a somewhat unusual record in view of their successes, and both times apparently entirely without foundation. A statement was published that the 1903 flight engine was a reworked Pope Toledo automobile unit, and it was repeated in an English lecture on the Wright brothers. This was adequately refuted by McFarland but additionally, it must be noted, there was no Pope Toledo company or car when the Wright engine was built. This company, an outgrowth of another which had previously manufactured one-and two-cylinder automobiles, was formed, or reformed, and a Pope license arrangement entered into during the year 1903.

The other incident was connected with Whitehead's activities and designs. Whitehead was an early experimenter in flying, about the time of the Wrights, whose rather extraordinary claims of successful flight were published in the 1901-1903 period but received little attention until very much later. His first engines were designed by a clever engineer, Anton Pruckner, who left at the end of 1901, after which Whitehead himself became solely responsible for them. It was stated that the Wrights visited the Whitehead plant in Bridgeport, Connecticut, and that Wilbur remained for several days, spending his time in their machine shop. This was not only categorically denied by Orville Wright when he heard of it but it is quite obvious that the 1903 or any other of the Wright engine designs bears little resemblance to Pruckner's work. In fact, its principal design features are just the opposite of Pruckner's, who utilized vertical cylinders, the 2-stroke cycle, and air-cooling, which Whitehead at some point changed to water-cooling.[15]

[Footnote 15: Considerable doubt surrounds Whitehead's actual flight accomplishments, but Pruckner's engines were certainly used, as several were sold to early pioneers, including Charles Wittemann. It is probable that the specific power output was not very great, for the air-cooled art of this time was not very advanced and Pruckner had a rather poor fin design. But the change to water cooling eliminated this trouble, and the engines were most simple, should have been relatively quite light, and with enough development could probably have been made into sufficiently satisfactory flying units for that period.]

The Four-Cylinder Vertical Demonstration Engine and the First Production Engine

In 1906, while still doing general development work on the flat experimental engine, the Wrights started two new engines, and for the first time the brothers engaged in separate efforts. One was "a modification of the old ones" by Wilbur and the other, "an entirely new pattern" by Orville. There is no record of any of the features of Wilbur's project or what was done in connection with it. Two months after the experimental operation of the two designs began, an entry in Wilbur's diary gives some weight and performance figures for the "4" x 4" rebuilt horizontal," and since Orville's design was vertical the data clearly refer to Wilbur's; but since the output is given only in test-fan rpm it does not serve to indicate what had been accomplished and there is no further mention of it.

Orville's design became the most used of any model they produced. It saw them through the years from 1906 to 1911 or 1912, which included the crucial European and United States Army demonstrations, and more engines of this model were manufactured than any of their others including their later 6-cylinder. Although its ancestry is traceable to the original 1903 engine, the design form, particularly the external configuration, was considerably altered. Along with many individual parts it retained the basic conception of four medium-size cylinders positioned in line and driving the propellers through two sprocket wheels. From the general tenor of the record it would seem, despite there being no specific indication, that from this time on Orville served as the leader in engine design, although this occurred with no effect whatsoever on their finely balanced, exactly equal partnership which endured until Wilbur's death in 1912.

The first major change from the 1903 design, putting the engine in an upright instead of flat position, was probably done primarily to provide for a minimum variation in the location of the center of gravity with and without a passenger. Whether or not it had any influence, the vertical cylinder arrangement was becoming predominant in automobile powerplants by this time, and the Wright engines now began to resemble this prevailing form of the internal combustion engine--a basic form that, in a wide variety of uses, was to endure for a long time.

Over the years, the Wrights seem to have made many changes in the engine: the bore was varied at different times, rod assembly methods were altered, and rod ends were changed from bronze to steel. Chenoweth states that on later engines an oil-control ring was added on the bottom of the piston, necessitating a considerable increase in the length of the cylinder barrel. This arrangement could not have been considered successful, as it apparently was applied to only a limited number of units and was not carried over to the later 6-cylinder engine model. There was much experimentation with cam shapes and most probably variations of these got into production.

With the crankcase, they did not go all the way to the modern two-piece form but instead retained the one-piece construction. Assembly was effected through the ends and a detachable plate was provided on one side for access to the interior. It is clear that they regarded this ability to get at the interior of the case without major disassembly as a valuable characteristic, and later featured it in their sales literature. They were apparently willing to accept the resultant weakening of the case and continued the construction through their last engine model. The integrally cast cylinder water jackets were abandoned and the top of the crankcase was machined flat to provide a mounting deck for individual cylinders. The use of aluminum alloy was continued, and the interior of the case was provided with strengthening webs of considerable thickness, together with supporting ribs. The cam shaft was supported directly in the case.

The individual cylinder design was of extreme simplicity, a single iron casting embodying everything except the water jacket. The valves seated directly on the cast-iron cylinder head and the guides and ports were all contained in an integral boss on top of the head. The exhaust valve location on the side of the engine opposite the pilot was a decided advantage over that of the 1903 design, where the exhaust was toward the pilot. A four-cornered flange near the bottom of the cylinder provided for fastening it to the crankcase, and a threaded hole in the top of the head received a vertical eyebolt which served as the rocker-arm support. The cylinder was machined all over; two flanges, one at the bottom and the other about two-thirds of the way down provided the surfaces against which the water jacket was shrunk. The jacket was an aluminum casting incorporating the necessary bosses and double shrunk on the barrel; that is, the jacket itself was shrunk on the cylinder-barrel flanges and then steel rings were shrunk on the ends of the jacket over the flanges. The jacket thickness was reduced by machining at the ends, making a semigroove into which the steel shrink rings fitted. These rings insured the maintenance of a tight joint despite the tendency of the aluminum jacket to expand away from the cast-iron barrel.