Cam Phaser Weld Layout to Prevent Cover Bulging
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Solution Overview
Problem
Existing cam phasers, particularly welded ones, suffer from deformation due to high pressure in pressure chambers, leading to bulging and require complex fabrication, resulting in instability and increased costs.
Innovation Solution
A method for producing a cam phaser with a rotor, stator, and cover where welds are formed on both large and small radii, with additional radial welds connecting them, using laser welding or hump welding to create a stable and simplified connection, preventing buckling and reducing fabrication complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cover is welded only at the outer circumference (large radius), then the fabrication is simpler, but the cover bulges outward under high pressure in the pressure chambers
Solution Approach 1:
The welding is segmented into multiple locations: welds at the large radius (outer circumference) and additional welds at the small radius (inner portion). This segmentation allows the welding structure to provide both simplicity and enhanced stability by distributing welds at strategically different radial positions rather than using a single continuous circumferential weld.
Solution Approach 2:
The solution adds a radial dimension to the welding pattern by introducing welds at two different radii (large radius and small radius) rather than only at the outer circumference. This radial distribution of welds creates a more stable connection that resists bulging while maintaining fabrication simplicity.
2Stability of the object's composition
If welds are added at both large radius and small radius, then the cam phaser stability improves and bulging is prevented, but the fabrication complexity increases
Solution Approach 1:
The welding pattern is segmented into discrete weld locations at large and small radii, allowing for controlled complexity. Rather than a continuous complex structure, the segmentation into specific weld points provides stability while keeping the fabrication process manageable and straightforward.
Solution Approach 2:
The welding provides local quality enhancement by placing welds at specific critical locations (large radius and small radius) rather than uniformly across the entire cover. This localized welding approach achieves maximum stability with minimum necessary complexity, addressing only the critical areas prone to bulging.
3Strength
If a continuous circumferential weld is formed at the large radius, then the connection between cover and stator is particularly stable, but the welding time and energy consumption increase
Solution Approach 1:
The continuous circumferential weld is segmented into discrete weld locations at large and small radii. This segmentation reduces the total weld length and welding time while maintaining connection strength by placing welds at strategically critical locations where they provide maximum structural benefit.
Solution Approach 2:
Instead of applying excessive welding throughout the entire circumference, the solution uses partial action by welding only at specific radii and locations. This provides sufficient connection strength to prevent bulging without the time and energy cost of continuous circumferential welding.
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 solution results in a more stable cam phaser that effectively prevents bulging under high pressure and simplifies the fabrication process, enhancing durability and reducing production costs.
Implementation Method 1
using laser welding or hump welding to create a stable and simplified connection
Implementation Method 2
welding the cover with the stator, wherein welds are formed at least on a large radius and/or on a small radius during welding
Data Source
AI summary
A method for producing a cam phaser for a cam shaft of an internal combustion engine, the cam phaser including a rotor, a stator and at least one cover, the method including arranging the at least one cover at the stator; and welding the at least one cover with the stator, wherein a first weld, a second weld and a third weld are formed at least on a large radius or on a small radius during the welding, and wherein the small radius is smaller than the large radius. The invention furthermore relates to a cam phaser for a cam shaft of an internal combustion engine, the cam phaser including a rotor; a stator and at least one cover.