Flexible Member for Electric Phaser Actuator Misalignment

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Solution Overview

Problem

Existing camshaft phaser systems face challenges in handling perpendicular and axial misalignment between electric camshaft actuators and camshaft phasers, leading to high internal friction and inefficiencies in torque transmission.

Innovation Solution

A flexible member is used to compensate for misalignment by being torsionally stiff in a rotational direction and flexible in an axial direction, operatively coupling the electric camshaft actuator with the camshaft phaser, and mechanically attached to both the output and input gears to transmit torque while reducing friction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a rigid connection is used between the electric camshaft actuator and the camshaft phaser, then torque transmission is direct and efficient, but misalignment between the actuator and phaser causes high internal friction and operational inefficiency

Engineering Contradiction:

Improvetorque transmission efficiencyVSAvoidinternal friction

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent employs a flexible plate member with a specific thickness-to-width ratio (thickness less than width and height) that acts as a flexible coupling between the actuator output gear and the phaser input gear. This flexible member can bend and deform to accommodate perpendicular and axial misalignment while maintaining torque transmission, thereby reducing internal friction caused by rigid misaligned connections.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible plate member changes its structural parameters (bending degree, deformation) based on the misalignment conditions. By allowing the plate to flex within certain limits, the system adapts to varying alignment conditions, reducing friction when misalignment occurs while maintaining sufficient stiffness for effective torque transmission when aligned.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If a flexible coupling is used to accommodate misalignment, then internal friction is reduced, but the structural complexity increases

Engineering Contradiction:

Improveinternal frictionVSAvoidstructural complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

Instead of using a complex multi-component flexible coupling mechanism, the patent employs a simple flexible plate member with optimized dimensions. The plate's flexibility is achieved through its geometric parameters (thickness less than width and height) rather than through complex mechanical structures, thereby reducing internal friction while minimizing added structural complexity.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible plate member serves multiple functions simultaneously: it transmits torque from the actuator to the phaser, accommodates perpendicular and axial misalignment, and reduces internal friction. This multi-functionality is achieved through a single component design, avoiding the need for multiple separate elements and thereby limiting the increase in structural complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If the flexible member is made thicker to increase stiffness, then torque transmission is improved, but the ability to compensate for misalignment is reduced

Engineering Contradiction:

Improvetorque transmissionVSAvoidmisalignment compensation

Core Design Contradiction:

PowerVSAdaptability or versatility

Solution Approach 1:

The patent optimizes the thickness parameter of the flexible plate member to achieve a balance between stiffness and flexibility. The thickness is specifically designed to be less than the width and height of the plate, creating an optimal ratio that provides sufficient torsional stiffness for torque transmission while maintaining enough flexibility to compensate for perpendicular and axial misalignment between the actuator and phaser.

Inventive Principle:

Principle #35Parameter changes

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 flexible member effectively compensates for misalignment, reducing high internal friction and improving torque transmission efficiency between the electric camshaft actuator and the camshaft phaser.

Implementation Method 1

A flexible member is used to compensate for misalignment by being torsionally stiff in a rotational direction and flexible in an axial direction

Methodology Applied

Scientific EffectTorsional stiffness:

Implementation Method 2

A flexible member is used to compensate for misalignment by being torsionally stiff in a rotational direction and flexible in an axial direction

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10316708B2Flexible member in electric phaser actuator

Publication Date: 2019.06.11 BORGWARNER INC

AI summary

A number of variations may include a product comprising a flexible member for an electric phaser actuator comprising: a plate, wherein the plate comprises a body; wherein the body has a thickness which is less than a width and a height of the body and wherein the body is constructed and arranged to attach to an output gear of an electric phaser actuator and wherein the body is constructed and arranged to mate with an input gear on a camshaft phaser.