Cam Phaser Cover Welding to Prevent Pressure Bulging
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Solution Overview
Problem
Existing cam phasers, particularly welded ones, face issues with cover deformation due to high pressure and complex fabrication processes, leading to instability and increased costs.
Innovation Solution
A cam phaser design featuring a flat circular cover integrally formed from sheet metal, sealed to a stator with a circumferential weld on both large and small radii, using laser welding for a stable and cost-effective connection, and optionally incorporating clover-shaped or hump welding for enhanced stability and simplicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded connection is used to connect the cover to the stator, then the connection strength is improved, but the cover deforms and bulges outward due to high pressure
Solution Approach 1:
The welding connection is divided into multiple segments: an inner circumferential weld at a smaller radius and an outer circumferential weld at a larger radius. This segmentation distributes the welding stress and provides multiple reinforcement points, preventing cover bulging while maintaining connection strength
Solution Approach 2:
Different welding positions are created at different radii - the inner weld at a first radius and the outer weld at a second radius. Each weld position provides localized reinforcement where needed, with the inner weld preventing bulging and the outer weld providing additional structural support
2Stability of the object's composition
If complex fabrication processes are used to prevent cover deformation, then the stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The fabrication process is segmented into distinct welding operations at different radii, making the complex process more manageable and systematic. The multiple welds provide stability through a structured approach rather than a single complex operation
Solution Approach 2:
The cover is positioned and contact-sealed to the stator before welding begins. This preliminary positioning ensures proper alignment and prevents deformation during the welding process, simplifying the overall fabrication by avoiding the need for complex positioning fixtures
3Strength
If multiple welds are made at different radii, then the resistance against buckling is improved, but the manufacturing time increases
Solution Approach 1:
The welding process is segmented into two circumferential welds at different radii that can be performed efficiently in sequence. The inner weld provides immediate buckling resistance, and the outer weld is added subsequently to enhance stability further
Solution Approach 2:
Traditional multi-step mechanical fastening or complex multi-phase welding processes are replaced with a streamlined two-circumferential-weld approach. This substitution maintains high buckling resistance while reducing manufacturing time through a simplified welding sequence
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
The solution provides a more stable cam phaser that prevents bulging under high pressure and simplifies fabrication, reducing material and production costs while maintaining high resistance against buckling and ensuring reliable sealing.
Implementation Method 1
welding and externally sealing the at least one cover with the stator by a closed circumferential weld along an outer edge of the at least one cover
Implementation Method 2
laser welding for a stable and cost-effective connection
Data Source
AI summary
A method for producing a cam phaser for a cam shaft of an internal combustion engine, the cam phaser including a rotor, a stator and at least one cover, the method including arranging the at least one cover at the stator wherein the at least one cover is a flat circular piece of sheet metal and the stator including internal vanes and external drive teeth is integrally provided from one piece of metal; sealing the at least one cover at the stator by applying a ground axial face of the at least one cover to a ground contact surface of the stator; and after the sealing.