3D-Printed Engine Maintenance Tool With Integrated Rotate-Locking
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Solution Overview
Problem
Existing engine maintenance tools for vehicles, such as camshaft position sensor clearance check tools, require multiple parts and materials, leading to complex assembly processes, potential loss of small components, and increased maintenance time.
Innovation Solution
A single-piece, additive manufactured assembly-free tool with an integrated bar, housing, and locking structure, made of stainless steel, tool steel, or titanium alloy, which is 3D-printed as one unit, eliminating the need for separate parts and assembly, and featuring a jagged structure and 'rotate-locking' mechanism for secure positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tool is manufactured as multiple separate parts requiring assembly, then manufacturing flexibility and adjustability are improved, but assembly complexity increases and small components may be lost
Solution Approach 1:
The patent merges multiple separate parts (outer housing, inner part, spring pin, screw) into a single integrated component manufactured via additive manufacturing. This consolidation eliminates assembly complexity and the risk of losing small components while maintaining the functional adaptability of the tool through integrated design features.
Solution Approach 2:
The single integrated tool head is designed to perform multiple functions: measurement, locking, and structural support. The additive manufacturing process enables complex geometries that combine these functions in one component, replacing the need for multiple specialized parts and their associated assembly steps.
2Adaptability or versatility
If multiple separate parts are used in the tool, then functional specialization is improved, but maintenance time and assembly steps increase
Solution Approach 1:
By combining all functional elements into one additive-manufactured component, the patent eliminates the time required for assembly and disassembly during maintenance. The integrated design maintains functional specialization through internally integrated features rather than separate components.
Solution Approach 2:
The tool is designed as a self-contained unit where all functional elements are permanently integrated. This eliminates the need for external assembly operations during maintenance, allowing the tool to be serviced as a single unit and reducing dependency on complex assembly procedures.
3Adaptability or versatility
If traditional manufacturing methods are used with multiple parts, then material selection flexibility is improved, but material usage and weight increase
Solution Approach 1:
The patent consolidates multiple parts into one, eliminating redundant material usage at interfaces and joints. Additive manufacturing enables optimized material distribution throughout the single component, reducing overall weight while maintaining structural integrity and functional requirements.
Solution Approach 2:
The additive manufacturing process allows for optimized material parameters and density distribution within the single component. This enables weight reduction through controlled material placement and optimized structural parameters, replacing the heavier multi-part construction.
4Reliability
If separate parts with different materials are used, then performance optimization for specific functions is improved, but manufacturing complexity and assembly precision requirements increase
Solution Approach 1:
By integrating all functional elements into one additive-manufactured component, the patent eliminates assembly precision requirements entirely. The single-component design maintains functional performance through internally integrated features, removing the need for precise mating between separate parts.
Data Source
AI summary
An assembly-free tool for maintenance of an engine in a vehicle is described. The tool comprises a bar extending in an axial direction and having a first portion with a first end and a second portion with a second end and a housing surrounding the first portion of the bar. The bar is axially translatable in relation to the housing. The housing comprises an embedded locking structure for holding the bar in a locking position to stop the movement of the bar in the axial direction. The bar, the housing and the locking structure are retained as one unit such that they are non-detachable from each other.