Elastic Clamping Actuator Support for Cam Phaser

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Solution Overview

Problem

Existing support arrangements for cam phaser actuators are limited in flexibility and cost-effectiveness, particularly in accommodating various installation positions and interfaces, and suffer from reliability issues due to welded or soldered contacts that are prone to damage from stress and vibrations.

Innovation Solution

A modular support arrangement featuring an actuator module connected to a support element via an elastic clamping element, allowing for adaptable installation positions and secure, releasable electrical contacting, with clamping arms forming an M-shaped receiver for stable actuator contact retention and ultrasound welding for cost-effective and durable assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a modular support arrangement with elastic clamping element is used, then adaptability and ease of manufacture are improved, but device complexity increases

Engineering Contradiction:

Improveinstallation position flexibilityVSAvoidsupport arrangement structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The support arrangement is divided into separate modular components: an actuator module and a support element that can be independently manufactured and then assembled. This segmentation allows each component to be optimized separately and facilitates adaptation to different installation positions without redesigning the entire system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The support element is designed as a universal component that can accommodate various actuator modules and adapt to different installation positions and customer-specific interfaces. The elastic clamping element provides a standardized connection mechanism that works across different configurations, reducing the need for custom-designed support structures for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If elastic clamping element is used for electrical contacting, then reliability is improved by compensating stresses, but manufacturing precision requirements increase

Engineering Contradiction:

Improveelectrical contact stabilityVSAvoidclamping element tolerance

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The elastic clamping element utilizes material elasticity parameters to create a compliant electrical connection. By selecting appropriate elastic materials and designing the clamping geometry to provide sufficient contact force, the system compensates for manufacturing tolerances and operational stresses while maintaining reliable electrical contact without requiring extremely tight precision controls.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If modular design with separate support element is used, then productivity is improved through standardized production, but device complexity increases

Engineering Contradiction:

Improveproduction volume capabilityVSAvoidassembly structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system is segmented into standardized modules that can be produced independently in high-volume manufacturing. The actuator module and support element are designed as separate interchangeable components, allowing parallel production streams and assembly line standardization, which significantly improves productivity while the modular nature manages complexity through repetition of proven designs.

Inventive Principle:

Principle #1Segmentation

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 modular design enables flexible installation and reduced production costs, extends service life by compensating for stress and vibrations, and prevents damage to electrical contacts, while allowing for customer-specific adaptations and precise positioning.

Implementation Method 1

the electrical contacting comprises an elastic clamping element... by means of the elastic clamping element, a fixed but still releasable electrical contacting is created. The clamp connection allows compensation for stresses and vibrations

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

ultrasound welding for cost-effective and durable assembly

Methodology Applied

Scientific EffectUltrasound: Ultrasound

Data Source

PatentUS10883394B2Support arrangement for an actuator of a cam phaser

Publication Date: 2021.01.05 ECO HLDG 1 GMBH

AI summary

A support arrangement for an actuator of a cam phaser, the support arrangement including an actuator module including an actuator; and a support element configured to support the actuator module on a camshaft, wherein the actuator module is connected to the support element by an electrical contact arrangement configured to actuate the actuator, and wherein the electrical contact arrangement includes an elastic clamping element.