Modular Cam Wheel Assembly for Variable Cam Belt Spacing
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Solution Overview
Problem
Existing cam wheels, particularly those used in agricultural machines and the process industry, are complex and costly to produce due to their cast component nature and require significant effort to adapt to cam belts with varying spacings, limiting flexibility and increasing production complexity.
Innovation Solution
A cam wheel design featuring tappet means projecting perpendicularly from a hub plate with reshaped shaft ends forming a closing head for clamping, allowing for flexible attachment and adaptation to different cam belt spacings, and utilizing a riveting-like process for assembly, enabling easy production and adaptation without complex tool changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cam wheels are produced as cast components, then structural strength and integrity are ensured, but production complexity and cost increase significantly
Solution Approach 1:
The cam wheel is divided into separate components: a hub and multiple tappet means that are attached to the hub. This segmentation allows each component to be manufactured independently using simpler, more cost-effective processes while maintaining overall structural integrity through the attachment mechanism.
Solution Approach 2:
Multiple tappet means are attached to a single hub, combining several functional elements into one assembly. This merging approach simplifies production by allowing standardized tappet means to be manufactured separately and then attached to the hub, reducing the complexity of producing a single complex cast component.
2Manufacturing precision
If cam wheels are designed as fixed cast components, then manufacturing precision is maintained, but adaptability to different cam belt spacings is reduced
Solution Approach 1:
The cam wheel design allows for dynamic configuration by enabling the attachment of different tappet means to the hub depending on the required cam belt spacing. This dynamic adaptability is achieved through the attachment mechanism that permits reconfiguration without requiring complex tool changes or remanufacturing.
Solution Approach 2:
The hub is designed as a universal component that can accommodate different types and configurations of tappet means. This universality allows the same hub to be used with various cam belt spacings by simply changing the attached tappet means, maintaining manufacturing precision while providing adaptability.
3Adaptability or versatility
If complex tool changes are implemented to adapt to different cam belt spacings, then adaptability is improved, but device complexity and production cost increase
Solution Approach 1:
Different configurations of tappet means are pre-prepared and can be stored in large quantities. This preliminary preparation allows for quick adaptation to different cam belt spacings by simply selecting and attaching the appropriate pre-fabricated tappet means, eliminating the need for complex tool changes during production.
Solution Approach 2:
Standardized tappet means are pre-fabricated as identical copies that can be attached to the hub in different configurations. This copying approach allows adaptability to different cam belt spacings using simple, standardized components rather than requiring complex, custom tooling for each configuration.
4Strength
If traditional attachment methods are used for tappet means, then structural integrity is maintained, but assembly complexity and time increase
Solution Approach 1:
The attachment method replaces traditional complex mechanical fastening systems with a simpler pressing-in mechanism. The tappet means are inserted into openings in the hub and secured through a pressing operation that deforms the tappet shaft to form a closing head, creating a strong attachment without requiring multiple fasteners or complex assembly steps.
Solution Approach 2:
The attachment process merges multiple operations into a single pressing action. The insertion, securing, and structural integration of the tappet means to the hub are accomplished in one continuous pressing operation, significantly reducing assembly time while maintaining attachment strength.
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 design facilitates a modular, quick, and cost-effective production of cam wheels that can be easily adapted to various cam belt spacings, reducing assembly complexity and minimizing costs while ensuring secure attachment and desired cam belt operation.
Implementation Method 1
the shaft is reshaped at its end to form a closing head such that the hub plate is clamped-in between the closing head and a shoulder
Data Source
AI summary
A cam wheel for accommodating a cam belt has a hub plate for mounting on a shaft and a plurality of cylindrical bolts including belt support areas for accommodating the cam belt. The cylindrical bolts are attached to the hub plate such that gaps are formed between the cylindrical bolts for accommodating cams of the cam belt in a positive locking manner. At a first end of the respective cylindrical bolts a shaft is formed which is inserted into an opening in the hub plate. The shaft is reshaped at its end to form a closing head in such a manner that the hub plate is clamped in between the closing head and a shoulder is formed between the shaft and the belt area support.