Variable-Thickness Cam Phaser Face Plate for Shorter Axial Length
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Solution Overview
Problem
Camshaft phaser assemblies face challenges in minimizing axial length while maintaining performance across variable operating conditions, often requiring compromises in valve timing that affect engine starting and high-speed operation.
Innovation Solution
A variable cam timing mechanism with a face plate of varying thickness, where the sum of thicknesses in contact with the stator and rotor equals the sum of thicknesses in contact with the outer and inner rings, along with a pin to prevent relative rotation, allows for reduced axial length without compromising durability or function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a variable cam timing mechanism is implemented to improve performance across variable operating conditions, then valve timing can be optimized for different speeds, but the axial length of the camshaft phaser assembly increases
Solution Approach 1:
The face plate is designed with variable thickness, having a first thickness in a first region and a second thickness less than the first thickness in a second region. This local variation in thickness allows the assembly to maintain adequate structural strength and durability in critical areas while reducing the overall axial length in non-critical areas, thereby resolving the contradiction between adaptability and compactness
Solution Approach 2:
The invention changes the thickness parameter of the face plate from a uniform value to a variable value across different regions. By optimizing the thickness distribution (first thickness in region 1, second thickness less than first in region 2), the design achieves both sufficient durability for variable cam timing operation and reduced axial length
2Length of moving object
If the axial length of the camshaft phaser assembly is reduced, then the overall size of the engine components decreases, but the durability and structural strength of the face plate are compromised
Solution Approach 1:
Rather than uniformly reducing thickness, the face plate employs local quality by having different thicknesses in different regions. The first region maintains a greater thickness to ensure durability and structural integrity, while the second region has a reduced thickness to minimize axial length, thus resolving the contradiction between compactness and reliability
Solution Approach 2:
The face plate is effectively segmented into regions with different thickness characteristics. This segmentation allows each region to be optimized independently - one region for strength and durability, another for space efficiency - thereby achieving both reduced axial length and maintained durability
Data Source
AI summary
A cam phaser mechanism includes an inner ring (rotor), and outer ring (stator), and a face plate. The inner ring that is wider than outer ring. The face plate is contoured such that it is thinner in a region in contact with the inner ring and thicker in a region in contact with the outer ring, thus compensating for the different widths of the inner ring and outer ring. The stator is fastened to the face plate by a plurality of bolts which are threaded into the face plate. The greater width of the face plate in this region provides sufficient thread engagement without increasing the overall width of the cam phaser mechanism.