Camshaft Adjuster Stator Cover Unit Assembly
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Solution Overview
Problem
The existing stator cover units for camshaft adjusters have high manufacturing and assembly complexity due to installation space restrictions and the inability to directly grip the locking cover during assembly, leading to potential imprecise assembly and assembly difficulties, especially when a restoring spring is involved.
Innovation Solution
A stator cover unit design that uses a projection on one component to engage with a recess on the other in a form-fitting manner, allowing for secure alignment and locking without direct circumferential gripping, utilizing an interference contour for precise coaxial alignment and generating a defined locking clearance through a restoring torque or spring, thus simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a two-part design with separate locking cover and stator is used, then assembly flexibility and precision are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The locking cover is nested within the stator, with the locking cover positioned inside the stator's internal cavity. This nesting arrangement allows the two-part design to achieve precise alignment through the form-fitting engagement between the locking cover's outer surface and the stator's inner surface, while avoiding the need for complex external fastening mechanisms.
Solution Approach 2:
A projection element acts as an intermediary between the locking cover and stator, engaging with a corresponding recess to establish precise rotational alignment. This intermediary feature enables accurate positioning without requiring complex gripping mechanisms or multiple fastening points, thereby reducing assembly complexity while maintaining precision.
2Volume of moving object
If the locking cover is positioned axially within another component, then space utilization is improved, but ease of assembly deteriorates due to inability to directly grip
Solution Approach 1:
The locking cover is designed with an integrated gripping feature that protrudes axially from the stator assembly, allowing assembly tools to directly engage with the locking cover itself rather than requiring manipulation of external components. This self-service feature enables workers to grip and rotate the locking cover during assembly despite its axial positioning within the stator, eliminating the need for complex auxiliary gripping mechanisms.
3Reliability
If a restoring spring is used with the locking cover, then locking reliability is improved, but assembly complexity increases due to pretensioning requirements
Solution Approach 1:
The restoring spring is pre-installed within the stator's internal cavity before the locking cover is assembled. The spring's one end is anchored to the stator, and its other end is positioned to engage with the locking cover's inner surface. This preliminary installation allows the spring to be pre-tensioned during stator manufacturing, eliminating the need for complex spring installation procedures during final assembly while maintaining reliable locking functionality.
Data Source
AI summary
A stator-cover unit (1) for a camshaft adjuster designed for use in an internal combustion engine, having a toothed ring (2) for receiving a torque, there being integrally connected to said toothed ring a stator (3) in the form of a housing, having a locking cover (4) which is separate from the stator (3), wherein the locking cover (4) is connected rotationally conjointly to the stator (3), wherein the stator (3) and the locking cover (4), at least during assembly, are held rotationally conjointly secured in said position by means of a projection (9) on one of the two components, which projection engages with a form fit into a recess (11) on the other of the two components. A camshaft adjuster having a rotor and having a correspondingly designed stator-cover unit (1), wherein a piston can be introduced, movably in an axial direction, into an opening of the locking cover (4).