Cam Phaser Spring Adapter for Assembly Testing
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Solution Overview
Problem
Existing cam phasers face challenges in efficient assembly and quality control due to preloaded spring tension, which complicates friction and pressure tests, and can lead to binding or excessive friction issues.
Innovation Solution
A vane-type cam phaser design that includes a spring element with a spring adapter and an axial fixing device, allowing for post-installation spring tension application, featuring a locking disc, contact ring, and fixing pins for precise alignment and preload, enabling unimpaired end-of-line inspection and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spring element is preloaded during assembly, then the cam phaser is ready for operation, but friction and pressure tests cannot be performed accurately and quality control is compromised
Solution Approach 1:
The spring element is segmented into two functional phases: an initial non-preloaded state for assembly and testing, and a subsequent preloaded state for operation. The spring adapter enables this segmentation by allowing the spring to be installed without preload, then later preloaded through rotation after the cam phaser is assembled. This resolves the contradiction by separating the testing phase from the operational phase.
Solution Approach 2:
The spring element transitions from a static non-preloaded state during assembly to a dynamic preloaded state during operation. The spring adapter facilitates this dynamic transition by enabling the spring to be preloaded in-situ after assembly through rotational movement, allowing accurate testing in the non-preloaded state while maintaining operational readiness.
2Productivity
If the spring element is preloaded during assembly, then the cam phaser is ready for operation, but binding or excessive friction issues occur that compromise quality control
Solution Approach 1:
The assembly process is segmented into distinct phases: assembly in non-preloaded state for reliability testing, followed by preload application. The spring adapter enables this segmentation by allowing the spring to be installed without tension, ensuring reliable friction measurements during assembly, then later preloaded through rotation for operational readiness.
Solution Approach 2:
The spring element is installed in a preliminary non-preloaded state that allows for reliable quality control and friction measurements. The spring adapter enables this preliminary action by facilitating installation without tension, ensuring that binding or excessive friction issues can be detected and resolved before the spring is preloaded for operation.
3Measurement precision
If the spring element is installed without preload, then accurate friction and pressure tests are possible, but the cam phaser requires additional steps to apply spring tension
Solution Approach 1:
The spring adapter serves multiple functions: it enables the spring element to be installed without preload for accurate testing, provides a mechanism for applying preload through rotation, and acts as a permanent fixing component. This multi-functionality resolves the contradiction by eliminating the need for separate preload application tools or steps while maintaining measurement accuracy.
Solution Approach 2:
The spring adapter enables the spring element to serve itself by providing an integrated mechanism for preload application. The adapter's inner contour allows the spring to be preloaded through rotation of the adapter itself, eliminating the need for external preload application devices or complex assembly steps.
4Productivity
If a fixed spring tension is applied during assembly, then the cam phaser is operationally ready, but end of line inspection and quality control are impaired
Solution Approach 1:
The spring element transitions from a static non-preloaded state during assembly and inspection to a dynamic preloaded state for operation. The spring adapter facilitates this dynamic transition by enabling the spring to be preloaded in-situ after the cam phaser is fully assembled and inspected, ensuring quality control is not impaired while maintaining operational readiness.
Solution Approach 2:
The spring element is installed in a preliminary non-preloaded state that allows for unimpaired end of line inspection and quality control. The spring adapter enables this preliminary action by facilitating installation without tension, ensuring that inspections can be performed accurately before the spring is preloaded for operational use.
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
Enables precise measurement of friction and pressure tests without initial spring tension, ensuring correct clamping and radial positioning, thus improving assembly efficiency and quality control.
Implementation Method 1
a spring element configured to align the rotor with the stator in an idle position
Implementation Method 2
Cam phasers of this type are used in valve trains of internal combustion engines in order to variably adjust a phase relationship between a crank shaft and a cam shaft
Data Source
AI summary
A vane type cam phaser for an internal combustion engine, the vane type cam phaser including a stator and a rotor that is rotatable relative to the stator to adjust a phase angle of a camshaft; a spring element configured to align the rotor with the stator in an idle position; a spring adapter that is arranged between the spring element and the rotor and an axial fixing device that fixes the spring adapter at the rotor.