Electric Camshaft Phaser Motor-Generator Energy Recovery
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Solution Overview
Problem
Existing electric camshaft phaser systems require a constant electric power supply, impacting fuel economy and emissions due to inefficiencies in energy usage during both phasing and non-phasing instances.
Innovation Solution
A cam phaser system with a control assembly and motor assembly that includes a bolt non-rotatably connected to the camshaft, allowing for torque transmission to a rotor to generate electrical energy, which is stored in an energy storage component, operating in two modes: camshaft phasing and camshaft locking modes, utilizing a hydraulic or electromechanical displacement assembly to selectively connect and disconnect the drive shaft for energy recovery during vehicle coasting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant electric power is supplied to the electric motor throughout IC engine operation, then the camshaft phasing control is maintained, but fuel economy and emissions are negatively impacted
Solution Approach 1:
The system dynamically switches between motor mode and generator mode based on operational conditions. The electric motor is disengaged during coasting conditions and re-engaged when phasing control is needed, making the energy consumption dynamic rather than constant. This resolves the contradiction by maintaining reliability only when necessary while improving fuel economy through conditional operation.
Solution Approach 2:
The system employs periodic engagement and disengagement of the motor assembly based on detected coasting conditions. During coasting, the motor is disengaged and the system operates in generator mode; when phasing is required, the motor re-engages. This periodic action pattern eliminates continuous energy consumption while maintaining required control functionality.
2Use of energy by moving object
If the motor assembly is disengaged during coasting conditions, then fuel economy is improved, but camshaft phasing control is lost
Solution Approach 1:
The system uses the kinetic energy from the camshaft rotation during coasting to generate electrical energy through the generator mode, which then powers the motor when phasing control is needed. The system serves itself by converting waste kinetic energy into usable electrical energy, eliminating the need for external power supply during coasting while maintaining control capability.
Solution Approach 2:
During coasting conditions, the system recovers kinetic energy from the camshaft rotation by operating the motor assembly in generator mode. This recovered energy is stored or used immediately when phasing control becomes necessary, transforming what would be wasted energy into a resource that maintains reliability without requiring constant external power supply.
3Loss of energy
If the electric motor operates in generator mode during coasting, then electrical energy is recovered, but additional mechanical complexity is introduced
Solution Approach 1:
The motor assembly is designed to perform multiple functions: it acts as a motor during phasing operations, as a generator during coasting energy recovery, and can be selectively engaged or disengaged based on operational mode. This multi-functionality eliminates the need for separate motor and generator components, reducing overall mechanical complexity while achieving energy recovery.
Solution Approach 2:
The patent merges the motor and generator functions into a single motor assembly that can operate in both modes. By combining these functions and using a single engagement mechanism controlled by the controller, the system reduces the number of separate components and simplifies the overall mechanical structure while still achieving energy recovery during coasting.
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 system enhances fuel economy and reduces emissions by enabling regenerative electrical energy generation during non-engine power output conditions, improving overall energy efficiency by converting kinetic energy into stored electrical energy.
Implementation Method 1
transmitting torque from the camshaft to a rotor of the motor assembly to generate electrical energy
Data Source
AI summary
A cam phaser is described for selectively engaging in a torque transmitting mode or an angle control mode. In the torque transmitting mode, torque from a camshaft is transmitted to an e-motor, which functions as a generator and provides electrical energy.