Assembled Camshaft with Multi-Tooth Profile and Roller-Burnished Sections
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Solution Overview
Problem
Existing methods for producing built-up camshafts often introduce excessive heat and unnecessary material waste, and fail to align fixed cam elements precisely in terms of angular orientation, particularly when combining axially displaceable and non-displaceable cam elements on a main camshaft body.
Innovation Solution
A method involving a bar-shaped main camshaft body with distinct axial sub-sections, where one section features a multi-tooth profile for axially displaceable cam elements and an enlarged section for non-displaceable elements, allowing for a non-positive/positive connection through mechanical roller-burnishing and the use of a hardenable filler to enhance strength, while maintaining simplicity and precision in assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional methods are used to produce built-up camshafts, then cam elements can be mounted on the camshaft, but excessive heat is introduced and unnecessary material waste occurs
Solution Approach 1:
The camshaft is divided into a main camshaft body and separate cam elements that can be independently manufactured and then assembled. This segmentation allows each component to be optimized separately, reducing overall heat introduction and material waste while maintaining manufacturing simplicity.
Solution Approach 2:
Cam elements are pre-manufactured with their final geometry and then assembled to the main camshaft body. This preliminary action allows precise control of each component's production process, minimizing unnecessary material waste and heat introduction during final assembly.
2Loss of substance
If conventional methods are used to produce built-up camshafts, then cam elements can be mounted on the camshaft, but unnecessary material waste occurs
Solution Approach 1:
The camshaft system is segmented into a main body and separate cam elements, allowing each to be manufactured efficiently with minimal material waste and then assembled through a simple connection process.
Solution Approach 2:
Cam elements are pre-formed with precise geometry before assembly, eliminating the need for excessive material removal during final mounting and reducing overall material waste in the production process.
3Manufacturing precision
If fixed cam elements are produced and assembled, then the camshaft can be built up, but precise angular orientation alignment is difficult to achieve
Solution Approach 1:
The camshaft is segmented into a main body and separate cam elements with standardized connection interfaces. This segmentation enables precise angular orientation to be achieved through simple alignment features during assembly, reducing the complexity of the alignment process.
Solution Approach 2:
Cam elements are pre-manufactured with precise angular features and connection geometries that facilitate accurate alignment with the main camshaft body, ensuring precise angular orientation is achieved automatically during the assembly process.
4Adaptability or versatility
If axially displaceable and non-displaceable cam elements are combined on the main camshaft body, then functional versatility is improved, but the production and alignment process becomes more complex
Solution Approach 1:
The camshaft system is segmented to allow different types of cam elements (axially displaceable and non-displaceable) to be independently manufactured and assembled onto the main body using standardized interfaces, maintaining process simplicity while enabling functional versatility.
Solution Approach 2:
The main camshaft body is designed with universal connection interfaces that can accommodate both axially displaceable and non-displaceable cam elements, allowing functional versatility without increasing production and assembly process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach minimizes heat introduction and material waste, simplifies the production and alignment of cam elements, and ensures cost-effective manufacturing with reduced risk of surface damage during assembly, while maintaining precise angular orientation and robust connections.
Implementation Method 1
a region of a main camshaft body which is roller-burnished and thus enlarged in terms of its outer diameter
Implementation Method 2
a hardenable material (in the form of a filler or the like) is introduced into the intermediate spaces of the structured surface of the main camshaft body which are produced by means of mechanical roller-burnishing, in order to increase the strength of the connection
Data Source
AI summary
A camshaft that is assembled or is to be assembled carries at least one cam element that is to be disposed on a main camshaft body to be rotationally fixed and axially movable, and at least one cam element to be disposed on the main camshaft body so as to be rotationally fixed and axially immovable. The main camshaft body has first axial sub-sections having a multi-tooth profile, so that due to a positive connection between shaft and hub the cam element to be disposed in the sub-section so as to be axially movable is seated so as to be rotationally fixed. The main camshaft body also has second axial sub-sections having an extended diameter so that by a non-positive connection between shaft and hub it is ensured that the cam element to be disposed in the sub-section is seated so as to be rotationally fixed and secured against movement.