Camshaft Phaser Integral Cover Play Elimination
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Solution Overview
Problem
Camshaft phasers experience reduced service life and reliability due to tolerance-induced play in form-locking connections, which leads to undamped pulses from vibrations, affecting acoustic behavior and component longevity.
Innovation Solution
Integrally formed play-elimination means on the cover element, such as local raised portions or abutments, ensure a permanently fixed seating by eliminating manufacturing-induced play through plastic deformation during assembly, preventing radial and circumferential play and compensating for material expansion differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If form-locking connections are used to join cover element and drive element, then manufacturing cost is reduced and assembly is simplified, but tolerance-induced play occurs leading to reduced service life and reliability
Solution Approach 1:
The patent combines the cover element and drive element into a single integrally formed plastic component, eliminating the form-locking connection interface that causes play. This merging resolves the contradiction by removing the source of tolerance-induced play while maintaining manufacturing efficiency through integral forming processes.
Solution Approach 2:
The patent extracts and eliminates the form-locking connection mechanism from the design. By removing the separate cover element and its connection to the drive element, the invention eliminates the tolerance accumulation and play that occur at the connection interface, thereby improving reliability without significantly increasing manufacturing complexity.
2Ease of operation
If form-locking connections with latching tabs are used, then assembly is simplified, but play becomes loose during operation reducing connection stability
Solution Approach 1:
By merging the cover element and drive element into one integral component, the patent eliminates the latching tab connection entirely. This resolves the instability issue caused by play in the connection while maintaining assembly simplicity through the inherent design of the integral structure.
3Stability of the object's composition
If wedge elements are added to prevent latching tabs from springing back, then connection stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the need for wedge elements by eliminating the form-locking connection entirely. The integral forming of the cover element and drive element creates a stable connection without requiring additional components like wedge elements, thereby maintaining connection stability while reducing device complexity.
Solution Approach 2:
The integral structure serves itself by providing inherent connection stability through its monolithic construction. The design eliminates the need for separate stabilization components like wedge elements, as the integral form inherently prevents play and springing back without additional parts.
4Manufacturing precision
If clearance exists between connection partners, then assembly tolerance is accommodated, but vibration-induced undamped pulses occur affecting acoustic behavior and service life
Solution Approach 1:
By merging the cover element and drive element into one integral component, the patent eliminates the clearance between connection partners. This resolves the issue of vibration-induced undamped pulses by removing the interface where such pulses occur, thereby improving reliability and service life while maintaining the ability to accommodate manufacturing precision through the integral forming process.
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 enhances reliability and service life by eliminating play-induced issues, ensuring a secure connection that withstands operational stresses and vibrations, thereby improving the camshaft phaser's performance and longevity.
Implementation Method 1
Integrally formed play-elimination means on the cover element, such as local raised portions or abutments, ensure a permanently fixed seating by eliminating manufacturing-induced play through plastic deformation during assembly
Implementation Method 2
The spring acting rotationally between the drive element and the output element impels the drive element in an advantageous direction relative to the output element
Implementation Method 3
the output element and the drive element form one or a plurality of pairs of pressure chambers which act in mutual opposition and can be pressurized by oil
Data Source
AI summary
A camshaft phaser (1), having a drive element (2), an output element (3), and a cover element (4), the cover element (4) being joined in latching-type, form-locking engagement with the drive element or output element (2, 3), and the cover element (4) having play-eliminator that eliminates a play in the connection.