Combined Plug-Sensor Wheel for Camshaft Sealing
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Solution Overview
Problem
Existing camshafts require separate and complex assembly of sensor wheels and plugs, leading to increased costs and complexity due to separate production processes and assembly steps.
Innovation Solution
A combined plug-sensor wheel with a pin projecting axially to seal the camshaft fluid-tight, integrating the functions of a sensor wheel for detecting valve positions and a plug for sealing, produced from sinter metal, plastic, or steel, allowing for a single production step and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate plugs and sensor wheels are used for camshaft assembly, then the sealing and sensing functions can be fulfilled, but the assembly complexity and production costs increase
Solution Approach 1:
The patent combines the plug and sensor wheel into a single integrated component called a combined plug-sensor wheel. This merging eliminates the need for separate assembly steps, reduces the number of parts, and simplifies the overall camshaft assembly process while maintaining both the sealing and sensing functions simultaneously
Solution Approach 2:
The combined plug-sensor wheel serves multiple functions within a single component: it provides sealing for the camshaft hollow interior, acts as a sensor wheel for detecting camshaft position, and serves as a structural element for mounting. This multi-functionality reduces the total component count and assembly complexity
2Ease of manufacture
If separate plugs and sensor wheels are assembled separately, then each component can be optimized independently, but the production time and costs increase
Solution Approach 1:
By merging the plug and sensor wheel into a single component, the patent enables production in one manufacturing process rather than requiring separate production and assembly steps. This significantly improves production efficiency and reduces manufacturing time while still allowing for material and design optimization
3Reliability
If multiple separate components are used for camshaft assembly, then functional requirements can be met, but material usage and costs increase
Solution Approach 1:
The integration of the plug and sensor wheel into a single component reduces the total material required for assembly. Instead of needing separate materials for a plug and a sensor wheel, the combined component uses a single material set, reducing material waste and inventory requirements
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 simplifies the assembly and production of camshafts and internal combustion engines by combining two functions into one component, reducing costs, material usage, and assembly complexity while ensuring a reliable and cost-effective sealing and sensing mechanism.
Implementation Method 1
plugs are employed which in turn are inserted into the camshaft at the longitudinal end side for example by way of a press-fit or thermal joining fit and, via the press-fit, are tightly connected to the same
Implementation Method 2
During sintering, metallic but also ceramic materials are heated under high pressure, wherein however the temperature reached in the process remains below the respective melting temperature of the main material, as a result of which the shape is retained
Implementation Method 3
via which an angle-of-rotation position of the respective camshaft and thus a valve opening position can be detected
Data Source
AI summary
A combined plug-sensor wheel for a camshaft is disclosed. The combined plug-sensor wheel includes a pin projecting in an axial direction of the camshaft. The pin, when inserted into the camshaft, seals the camshaft in a fluid-tight manner. According to an implementation, the combined plug-sensor wheel and the camshaft are incorporated into an internal combustion engine.