Camshaft Phaser Lock Mechanism Torque Control
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Solution Overview
Problem
Conventional camshaft phaser systems are complex and costly to manufacture, with a need for reduced dimensions and improved operational characteristics such as engine performance and efficiency.
Innovation Solution
A camshaft phaser system with a phaser actuated by an electric motor, comprising a first portion in rotational communication with the crankshaft, a second portion operatively attached to the camshaft, and a third portion attached to the electric motor, featuring a lock or lever spring mechanism that moves between positions in response to torque differentials to control the phase angle, reducing complexity and cost while enhancing performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional camshaft phaser systems are used, then the system provides basic phase control capability, but the system complexity and manufacturing cost increase
Solution Approach 1:
The phaser is divided into multiple portions (first portion in rotational communication with crankshaft, second portion with camshaft, third portion with actuator) that can independently rotate relative to each other. This segmentation allows simplified control mechanisms while maintaining phase control capability through the modular structure.
Solution Approach 2:
The lock mechanism automatically engages and disengages based on torque differentials between the actuator and camshaft without requiring additional control systems. The system self-regulates the phase angle by allowing the lock to move between first position (rotatable) and second position (locked) in response to torque conditions.
2Ease of manufacture
If conventional phaser designs are used, then basic phase control is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
Multiple functions are merged into single components: the lock mechanism serves both as a positioning device and a torque-sensing element, the three portions of the phaser integrate rotational communication paths, and the receiver-lock interface combines engagement and disengagement functions. This merging reduces the number of separate parts and simplifies manufacturing.
Solution Approach 2:
The lock mechanism serves multiple purposes: it locks the phase angle at predetermined positions, senses torque differentials, and automatically engages/disengages based on operating conditions. The receiver structure similarly provides both engagement surface and structural support, reducing the need for separate components.
3Reliability
If the phaser includes lock mechanism with multiple positions, then operational control and engine performance improve, but the dimensions and packaging space increase
Solution Approach 1:
The lock mechanism is nested within the phaser structure, with the lock and receiver integrated into the existing three-portions architecture. The lock can be positioned within the phaser body or on the actuator, utilizing existing spaces rather than adding external components. This nesting allows the lock to provide multiple locking positions without significantly increasing the overall phaser volume.
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 system significantly reduces the complexity and packaging size of camshaft phaser systems, achieving superior operational characteristics like improved engine performance, control, and efficiency while lowering manufacturing costs.
Implementation Method 1
The lock is movable between the first position and the second position in response to a predetermined torque differential occurring between the actuator and the camshaft
Implementation Method 2
The electric motor and phaser are operatively attached to each other and in rotational communication so as to allow rotation of the electric motor to adjust the phase angle of the camshaft
Data Source
AI summary
A system (44) for controlling camshaft (28) phase in an engine (20) with a crankshaft (26), including: an actuator (42) driving a phaser (38) attached to the camshaft (28). The phaser (38) has a first portion (46) in communication with the crankshaft (26), a second portion (48) attached to the camshaft (28) and in communication with the first portion (46), and a third portion (50) attached to the actuator (42) and in communication with the second portion (48). One portion includes a receiver (52), and another portion includes a lock (54) having: a first position (78) where the portions with the receiver (52) and lock (54) can rotate with respect to each other; and a second position (80) where the portions with the receiver (52) and lock (54) are coupled. The lock (54) moves between positions in response to predetermined torque differential between the actuator (42) and camshaft (28).