Harmonic Camshaft Adjuster Assembly for Precise Gear Alignment
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Solution Overview
Problem
Existing methods for assembling electromechanical camshaft adjusters lack reliability and introduce mechanical overspecifications, particularly in the alignment and assembly of harmonic drive components, which affects the precision and efficiency of the camshaft adjustment process.
Innovation Solution
A method for assembling an actuating gear of an electromechanical camshaft adjuster using a harmonic drive design, involving a ring gear drive wheel, an internally toothed output element, and a flexible gear element, where the internal toothing alignment is facilitated by a wave generator and screw connection, with optional assembly aids like annular grooves and recesses to ensure precise alignment and sealing, allowing for a high-reduction gear mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly methods are used for harmonic drive components, then assembly process is simpler, but alignment precision and process reliability deteriorate
Solution Approach 1:
A positioning element is introduced as an intermediary component between the drive wheel and the output element. This positioning element features a conical surface that cooperates with a corresponding conical surface on the output element, enabling precise angular and radial alignment during assembly without requiring complex alignment procedures or specialized tooling.
Solution Approach 2:
The positioning element is pre-installed on the drive wheel before the output element is assembled. The conical surfaces are pre-positioned to define the correct alignment, so that when the output element is installed, the alignment is automatically achieved without requiring subsequent adjustment or complex assembly procedures.
2Measurement precision
If precise alignment of internally toothed elements is required, then camshaft adjustment precision is improved, but assembly difficulty increases
Solution Approach 1:
The positioning element serves as a mediator that transfers the alignment function from the final assembly step to a preliminary installation step. By pre-installing the positioning element with its conical alignment surfaces, the system automatically guides the output element into the correct position, eliminating the need for complex alignment operations during final assembly.
Solution Approach 2:
The conical surfaces of the positioning element and output element create a self-aligning mechanism. When the output element is installed, the conical surfaces automatically guide it into the correct angular and radial position without requiring external alignment tools or complex adjustment procedures, making the assembly process straightforward while ensuring high precision.
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 method enhances process reliability and avoids mechanical overspecifications by ensuring precise alignment and sealing of the actuating gear components, improving the efficiency and precision of the camshaft adjustment process, particularly suitable for series production conditions.
Implementation Method 1
an externally toothed flexible gear element, in particular in the form of a flex ring, which surrounds a wave generator
Implementation Method 2
The further internally toothed element is fixed by means of a screw connection
Data Source
AI summary
A harmonic drive of an electromechanical camshaft adjusters includes a drive wheel designed as a ring gear; an internally toothed output element mounted with radial play in the drive wheel; a further internally toothed element fastened to the drive wheel, the internal toothing of which has a diameter corresponding to the internal toothing of the output element; an adjuster assembly which is formed from a wave generator; an externally toothed flexible gear element which can be deformed by said wave generator, the external toothing of this flexible gear element meshing both with the internal toothing of the output element and with the internal toothing of the further element; an annular gap being formed between the further internally toothed element and an inner peripheral surface of a recess of the drive wheel. The width of the annular gap is at least partially greater than a radial play of the output element.