Camshaft Phaser Insertion Piece Stepped Rotor Design
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Solution Overview
Problem
The existing camshaft phaser design is costly and complex due to the need for expensive turning and spinning processing to form a stepped center hole in the rotor, and the fixing pin requires a large space, leading to interference and structural complexity.
Innovation Solution
An insertion piece with a stepped cylindrical shape is used to form the center hole of the rotor, eliminating the need for these processes and replacing the fixing pin, thereby simplifying the structure and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If turning and spinning processing is used to form the stepped center hole in the rotor, then the rotor can be assembled with the central valve and camshaft, but the manufacturing cost increases significantly
Solution Approach 1:
The rotor assembly is segmented into two parts: the rotor body and a separate insertion piece. The insertion piece contains the stepped center hole structure, which is assembled into the rotor body. This segmentation allows the stepped structure to be formed by simpler processing methods on the insertion piece rather than requiring complex turning and spinning processing on the entire rotor, thereby reducing manufacturing cost while maintaining precision.
Solution Approach 2:
The insertion piece acts as an intermediary component that provides the stepped center hole structure. Instead of directly forming the complex stepped structure in the rotor body through expensive processing, the insertion piece serves as a mediator that can be manufactured more economically and then assembled into the rotor, achieving the required precision at lower cost.
2Ease of operation
If the fixing pin is mounted on the rotor body to fix the coil spring, then the spring can be secured, but the fixing pin protrudes much more than the rotor body and requires large mounting space
Solution Approach 1:
The fixation function is merged into the insertion piece itself. The insertion piece incorporates a fixation structure (such as a groove or clamping feature) that directly secures the coil spring, eliminating the need for a separate protruding fixing pin. This integration reduces the axial space requirement while maintaining the spring fixation capability.
Solution Approach 2:
Instead of extending the fixation structure axially outward from the rotor body (one-dimensional protrusion), the fixation function is implemented within the radial and axial dimensions of the insertion piece that fits into the rotor's center hole. This dimensional reorganization allows spring fixation without requiring excessive axial protrusion.
3Reliability
If the fixing pin with head is used to mount the coil spring, then the spring can be securely fixed, but the structure becomes complex and expensive
Solution Approach 1:
The fixation function is combined with the insertion piece structure. The insertion piece includes integrated fixation features (such as grooves, slots, or clamping surfaces) that directly secure the coil spring, eliminating the need for a separate fixing pin with head. This merging reduces structural complexity while maintaining reliable spring fixation.
Solution Approach 2:
The complex fixing pin with head is extracted from the rotor assembly and its function is integrated into the simpler insertion piece. This extraction and integration simplifies the overall rotor structure while maintaining the necessary spring fixation reliability through the insertion piece's built-in fixation features.
4Length of moving object
If the center hole has stepped structure formed by turning and spinning processing, then the rotor can accommodate central valve and camshaft, but the rotor axial width increases
Solution Approach 1:
The rotor assembly is segmented into the rotor body and a separate insertion piece. The stepped center hole structure is formed on the insertion piece, which can be manufactured with simpler processing methods. This segmentation allows the stepped structure to be achieved without increasing the overall rotor axial width, as the insertion piece fits within the existing space.
Solution Approach 2:
Instead of forming the stepped structure by extending the rotor axially outward (increasing axial width), the stepped structure is implemented within the radial dimensions of the insertion piece that fits into the rotor's center hole. This dimensional approach maintains compact axial width while achieving the required structural complexity through radial features.
Data Source
AI summary
The present disclosure relates to an insertion piece for a camshaft phaser and the camshaft phaser. The insertion piece is configured to be partially inserted and mounted into a center hole of the rotor of the camshaft phaser. The insertion piece has a stepped cylindrical shape across its entirety and includes a first cylinder portion, a second cylinder portion, and a third cylinder portion, which are connected to each other and are coaxially arranged. The first cylinder portion extends along the axial direction; the second cylinder portion is located at one axial side of the first cylinder portion and extends along the axial direction; the third cylinder portion is located at one axial side of the second cylinder portion and extends along the axial direction; and a clamping connection portion for fixing the coil spring of the camshaft phaser is formed on the third cylinder portion.