Variable Cam Phaser Magnetic Coupling Power Reduction

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Solution Overview

Problem

Current cam phaser systems face challenges in operating at extreme temperatures, particularly during engine startup, and suffer from high power consumption due to complex triple shaft gear systems that require continuous actuator power to control cam phase changes.

Innovation Solution

A cam phaser apparatus with a triple member gear system, including a selectively actuable magnetic coupling between the drive, driven, and adjusting members, allowing synchronous rotation and torque application to adjust cam phase without continuous actuator power, using a magnetic coupling mechanism to constrain rotation and apply braking or motoring torque as needed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a triple shaft gear system is used to adjust cam phase, then the cam phase can be varied, but the actuator must be powered at all times to prevent uncontrolled cam phase change, leading to high power consumption

Engineering Contradiction:

Improvecam phase adjustment capabilityVSAvoidpower consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The patent extracts the continuous power requirement from the system by introducing a selective coupling mechanism. The coupling means can disengage the actuator from the triple shaft gear system when cam phase adjustment is not needed, allowing the system to operate without continuous actuator power while maintaining the ability to adjust cam phase when required.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent applies dynamics by making the coupling between the actuator and the triple shaft gear system variable rather than fixed. The selective coupling means can engage or disengage based on operational requirements, allowing the actuator to be connected only when cam phase adjustment is needed, thereby reducing overall power consumption while maintaining adaptability.

Inventive Principle:

Principle #15Dynamics

2Device complexity

If hydraulic actuators are used for cam phase adjustment, then the system can operate with simple mechanics, but the system fails to operate reliably at extreme temperatures due to oil viscosity changes

Engineering Contradiction:

Improvemechanical simplicityVSAvoidoperational reliability at extreme temperatures

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces the hydraulic actuation system with an electric actuation system. This substitution eliminates the temperature-sensitive hydraulic fluid and viscosity-related reliability problems while maintaining mechanical simplicity through the use of an electric motor coupled with a selective coupling mechanism to the triple shaft gear system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If triple shaft gear systems are used for cam phase variation, then the cam phase can be adjusted, but the position and angular velocity of the third shaft must be controlled at all times, introducing controllability problems

Engineering Contradiction:

Improvecam phase variation capabilityVSAvoidcontrollability

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The patent extracts the continuous control requirement from the triple shaft gear system by introducing a selective coupling mechanism. The coupling means can disengage the actuator from the third shaft when cam phase adjustment is not needed, eliminating the need for continuous position and angular velocity control while maintaining the ability to vary cam phase when required.

Inventive Principle:

Principle #2Taking out (Extraction)

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 solution enables efficient adjustment of cam phase while reducing power consumption by synchronizing the rotation of all three members during idle conditions, minimizing unnecessary motor power usage and improving system reliability.

Implementation Method 1

said coupling means comprises a magnetic coupling, more preferably an electromagnetic coupling

Methodology Applied

Scientific EffectMagnetic coupling: Magnetic Field

Implementation Method 2

the other of said first and second members incorporating means for selectively generating a magnetic flux to constrain the first and second members to rotate together

Methodology Applied

Scientific EffectElectromagnetic coupling: Electromagnetic Induction

Data Source

PatentUS7647904B2Variable cam phaser apparatus

Publication Date: 2010.01.19 DELPHI INT OPERATIONS LUXEMBOURG SARL

AI summary

A cam phaser apparatus comprising a triple member gear system for transferring a driving torque from a drive member to a driven member and for selectively adjusting the angular relationship between the drive and driven members, said triple member gear system comprising a first member comprising a driving part, a second member comprising a driven part connectable to a cam sprocket or pulley, and a third member comprising an adjusting means connectable to a camshaft, said third member being connected to means for rotating said third member or applying a braking torque and/or a motoring torque to said third member to vary the angular relationship between the first and second members, wherein the cam phaser apparatus further comprises a selectively actuable coupling means for selectively coupling two of said first, second and third members. In one embodiment the coupling means comprises a magnetic coupling.