Cam Phaser Piston Contour for Housing-Free Hydraulic Control
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Solution Overview
Problem
Hydraulic units for cam phasers in internal combustion engines face challenges with reliability, cost-effectiveness, leakage, and flow efficiency due to the need for a piston housing, which increases production costs and weight, and limits adjustment speed.
Innovation Solution
A piston configured to be axially movable within the cam phaser opening without a housing, featuring a complementary outer and inner contour for direct positioning, eliminating the need for additional housing elements, and including control edges and a terminal cover for secure fluid supply and positioning, reducing leakage and enhancing fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piston housing is used to receive the piston, then the piston can be positioned and controlled, but the device complexity, weight, and production cost increase
Solution Approach 1:
The patent removes the piston housing from the hydraulic unit, extracting this component entirely. The piston is positioned directly in the cam phaser opening using complementary contours between the piston outer surface and cam phaser inner surface, eliminating the need for a separate housing structure while maintaining positioning reliability
Solution Approach 2:
The patent merges the piston directly with the cam phaser structure by using complementary contours that enable direct positioning. The piston outer contour and cam phaser inner contour work together to provide positioning and connection control without requiring an intermediate housing, thus combining functions into fewer components
2Reliability
If a piston housing is used, then the piston can be contained, but the production cost and weight increase
Solution Approach 1:
The piston housing is extracted and removed from the design. The piston is contained through direct geometric interfacing between the piston outer contour and cam phaser inner contour, eliminating the additional weight of the housing structure while maintaining containment functionality
Solution Approach 2:
The unnecessary piston housing component is discarded from the design. The weight and cost associated with this component are eliminated, while the containment function is recovered through the complementary contour design that provides direct positioning and sealing
3Ease of operation
If a piston housing with opening connections is used, then fluid flow can be controlled, but leakage increases and flow efficiency decreases
Solution Approach 1:
The piston housing with its opening connections is extracted and removed. Fluid flow control is achieved directly through the cam phaser opening and piston positioning, eliminating the additional sealing interfaces and potential leakage paths that would exist with a separate housing structure
Solution Approach 2:
The complementary contour design creates a direct sealing interface between the piston and cam phaser opening. This thin-film-like contact surface provides effective sealing without requiring additional sealing elements or complex housing structures, reducing leakage while maintaining flow control
4Ease of operation
If a piston housing is used, then the piston can be positioned axially, but the adjustment speed decreases
Solution Approach 1:
The piston housing is removed, eliminating the additional interface and potential friction points between the housing and piston. This reduces resistance to axial movement and allows faster adjustment speeds while maintaining positioning capability through the complementary contour design
Solution Approach 2:
The direct contact between the piston outer contour and cam phaser inner contour creates a low-friction interface that facilitates rapid axial movement. This thin-film-like contact reduces resistance compared to a housing-based system, enabling faster adjustment speeds
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 configuration reduces production costs, minimizes fluid leakage, increases flow efficiency, and enhances adjustment speed by eliminating the piston housing, leading to a more reliable and cost-effective cam phaser with reduced weight and installation space requirements.
Implementation Method 1
a piston (24) configured cylindrical and received axially movable in a cam phaser opening (18) wherein various connections (A, B) of the cam phaser can be opened and/or blocked corresponding to a position of the piston (24)
Data Source
AI summary
A piston for a hydraulic unit of a cam phaser, wherein the piston is configured cylindrical and wherein the piston is received axially movable in a cam phaser opening of the cam phaser, wherein according to a positioning of the piston a plurality of connections, in particular operating connections of the cam phaser are opened and closed, wherein the piston includes an outer contour that is configured for opening or closing the connections wherein the outer contour is configured complementary to an inner contour of the cam phaser opening in order to provide opening and/or closing of the connections. The invention also relates to a cam phaser.