Hollow Shaft Module Assembly for Torque-Rigid Attachment Positioning
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Solution Overview
Problem
Existing methods for joining composite shafts in engine modules, such as cam shafts, face limitations in achieving accurate axial and rotational positioning, leading to potential engine damage and increased costs due to the need for precise thermal expansion and interference fits, which can result in relative rotation between components.
Innovation Solution
A method involving the plastic deformation of a hollow shaft to securely fix attachment parts, such as cams and gear wheels, by widening the shaft's support sections to create a torque-proof connection without the need for thermal processing or extensive post-processing, allowing for a stable and reliable assembly at room temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal joining with cooling and heating is used to create interference fit, then the components can be attached to the support shaft, but the process becomes complex and requires precise temperature control to avoid material damage
Solution Approach 1:
The patent replaces the thermal joining process with a mechanical pressing-in process. Instead of using thermal expansion and contraction to create interference fit, the support shaft is directly pressed into the components at room temperature. This mechanical approach eliminates the need for heating and cooling equipment, simplifying the joining process while maintaining joint strength.
Solution Approach 2:
The patent changes the joining parameters from thermal (temperature-based) to mechanical (force-based). By applying pressing force directly to the support shaft and components, the interference fit is achieved through mechanical deformation rather than thermal expansion/contraction, avoiding material damage while simplifying the process.
2Reliability
If high interference fit is used to prevent relative rotation, then torque transmission is improved, but the pressing-in force required increases and may damage components
Solution Approach 1:
The patent performs preliminary positioning and alignment of the support shaft and components before the pressing-in operation. By pre-positioning the components in their correct relative orientations and using guiding structures, the pressing-in process requires less force to achieve the same interference fit, preventing component damage while ensuring proper torque transmission alignment.
3Manufacturing precision
If precise axial and rotational positioning is achieved through thermal expansion, then component alignment is improved, but the process time and energy consumption increase
Solution Approach 1:
The patent implements preliminary positioning features such as tapered sections, alignment grooves, and pre-drilled holes that guide the support shaft and components into their correct positions during assembly. This eliminates the need for time-consuming thermal processing to achieve alignment, as the mechanical features automatically ensure precise axial and rotational positioning during the pressing-in operation.
4Strength
If thermal processing is used to join components, then material properties can be optimized, but energy consumption and environmental impact increase
Solution Approach 1:
The patent replaces the energy-intensive thermal processing system with a mechanical pressing-in system. By using hydraulic or mechanical presses to apply controlled force to the support shaft and components, the joining process achieves the same joint strength without requiring heating equipment, significantly reducing energy consumption and environmental impact.
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 method reduces manufacturing and assembly costs, enhances process reliability, and ensures a strong, torque-transmitting joint with reduced material and energy usage, eliminating the need for thermal expansion and minimizing post-processing efforts.
Implementation Method 1
the hollow shaft is plastically deformed in the region of its support sections
Implementation Method 2
at least one attachment part of the at least one attachment part is elastically deformed
Data Source
AI summary
A method of joining a functional module comprises the steps of providing a frame structure that defines a bearing channel with at least one circumferentially closed bearing seat; providing at least two attachment parts; providing a hollow shaft that comprises at least one support section for the at least two attachment parts, wherein the attachment parts comprise a mounting seat that is adapted to a support section; feeding the attachment parts in the bearing channel in a first feeding direction; feeding the hollow shaft in the bearing channel in a second feeding direction, wherein the hollow shaft is inserted into the respective mounting seat of the at least two attachment parts; and, subsequent to the feeding of the attachment parts and the hollow shaft in the bearing channel, at least sectionally widening the hollow shaft for a torsionally rigid fixation of the at least two attachment parts with their mounting seats at the respective support section of the hollow shaft.