Camshaft Connector Protrusions Eliminate Large Bolt
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric-hydraulic camshaft phaser assemblies require a large, costly bolt for connecting the output gear of the electric camshaft phaser to the camshaft, which is inefficient in terms of material usage and machining complexity.
Innovation Solution
The assembly employs non-threaded protrusions fixed to the output gear, which are inserted into slots of the camshaft to transmit rotational torque, eliminating the need for a large bolt and simplifying the connection process by reducing material and machining requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a large bolt is used to connect the output gear to the camshaft, then the connection strength is sufficient, but the material usage and machining complexity increase
Solution Approach 1:
The single large bolt connection is segmented into multiple smaller protrusions (at least one protrusion, preferably two or more) that are distributed around the output gear. Each protrusion fits into a corresponding slot in the camshaft, distributing the connection function across multiple smaller elements rather than one large element.
Solution Approach 2:
The connection approach transitions from a single-point axial connection (bolt) to a distributed radial connection pattern. The protrusions extend axially from the output gear face and engage with slots in the camshaft, utilizing the radial distribution of multiple engagement points to achieve both strength and simplicity.
2Reliability
If a large bolt is used to connect the output gear to the camshaft, then the connection is reliable, but the material usage increases
Solution Approach 1:
The material of a single large bolt is segmented into multiple smaller protrusions made from the output gear material itself. This eliminates the need for a separate large bolt component and reduces overall material consumption while maintaining connection reliability through distributed engagement.
Solution Approach 2:
The protrusions are integrated directly into the output gear structure rather than being separate components. This merging of the connection elements with the gear body reduces the total material required and eliminates the need for separate fastener materials.
3Power
If a large bolt is used to connect the output gear to the camshaft, then the torque transmission is effective, but the device complexity increases
Solution Approach 1:
The torque transmission function is segmented across multiple protrusion-slot interfaces rather than relying on a single bolt interface. Each protrusion transmits a portion of the torque, and the combined effect of multiple interfaces provides effective torque transmission while simplifying the overall connection structure.
Solution Approach 2:
The slots in the camshaft act as intermediaries that receive and guide the protrusions from the output gear. This intermediary structure enables effective torque transmission through a simple geometric interface rather than requiring complex threaded fasteners.
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
This solution reduces the material and machining complexity, lowering costs and simplifying the connection between the electric camshaft phaser and the camshaft, while maintaining effective rotational torque transmission.
Implementation Method 1
The at least one protrusion is arranged to transmit rotational torque from the output gear to the second camshaft
Data Source
AI summary
An electric-hydraulic camshaft phaser assembly, including a hydraulic camshaft phaser and an electric camshaft phaser. The hydraulic camshaft phaser includes: a stator arranged to receive rotational torque and including a plurality of radially inwardly extending protrusions; a rotor arranged to be non-rotatably connected to a first camshaft and including a plurality of radially outwardly extending protrusions circumferentially interleaved with the plurality of radially inwardly extending protrusions; and a plurality of chambers bounded at least in part by the plurality of radially inwardly extending protrusions and the plurality of radially outwardly extending protrusions. The electric camshaft phaser includes: an input non-rotatably connected to the stator; an output gear; and at least one protrusion fixed to the output gear and arranged to be inserted into at least one slot of a second camshaft. The at least one protrusion is arranged to transmit rotational torque from the output gear to the second camshaft.