Motor Vehicle Module Assembly Using Thermal Expansion and Press Fits
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Solution Overview
Problem
Existing methods for assembling motor vehicle modules, such as camshaft arrangements, face challenges in achieving high load capacity and wear resistance, while also requiring complex surface machining and precise alignment of components.
Innovation Solution
The method involves using roller bearings in the bearing mounts of the housing part to create a press fit with the shaft, allowing for low friction, simplified assembly, and the ability to absorb tilting moments, with a combination of transverse and longitudinal press fits for secure attachment of the shaft and functional elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If roller bearings are used in bearing mounts to improve load capacity and wear resistance, then the reliability and load-bearing capability are improved, but the device complexity and assembly difficulty increase due to the need for precise press fit alignment
Solution Approach 1:
The patent utilizes temperature changes as a parameter to facilitate assembly. The housing part is heated and the shaft is cooled to create thermal expansion/contraction that enables easy insertion of roller bearings and shaft assembly, eliminating complex alignment procedures while maintaining high load capacity and wear resistance
Solution Approach 2:
The patent explicitly applies thermal expansion by heating the housing part and cooling the shaft to create dimensional changes that facilitate assembly. The thermal expansion of the housing bore and contraction of the shaft enable interference fit of roller bearings and smooth insertion without complex machining or alignment tools
2Manufacturing precision
If complex surface machining is performed on bearing mounts to achieve precise alignment, then the manufacturing precision is improved, but the manufacturing cost and time increase
Solution Approach 1:
The patent replaces complex surface machining with temperature parameter changes. By heating the housing part and cooling the shaft, the patent achieves precise dimensional control and alignment without time-consuming machining operations, thereby improving both manufacturing precision and productivity
Solution Approach 2:
The patent substitutes mechanical machining operations with thermal processing. Instead of using complex machining tools and procedures to achieve precise alignment, the patent uses controlled heating and cooling to achieve the same alignment precision more efficiently
3Strength
If interference fit is created between hub opening and thickening to secure functional elements, then the strength and positional stability are improved, but the assembly effort increases due to the force required for pressing
Solution Approach 1:
The patent applies thermal expansion by heating the housing part containing the hub opening and cooling the shaft with thickening. This creates dimensional changes that reduce interference during assembly, allowing functional elements to be secured with strong interference fits without requiring excessive pressing force
Solution Approach 2:
The patent uses temperature parameter changes to modify the dimensional properties of components during assembly. By controlling temperature, the patent achieves both strong interference fits for positional stability and reduced assembly effort through thermal facilitation
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 approach results in a motor vehicle module with improved load capacity and wear resistance, reduced assembly complexity, and enhanced reliability, enabling smooth operation under varying loads and torques.
Implementation Method 1
Generating a temperature difference between the housing part and the shaft, with which the shaft is inserted into the housing
Implementation Method 2
Bringing about a temperature equalization between the shaft and the housing part; creating an interference fit between the hub opening and the associated thickening
Data Source
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AI summary
The invention relates to a method for assembling a motor vehicle module that has a shaft (1), which is provided with at least one functional element, and a housing part (2). The shaft (1) is rotatably arranged in bearing receiving portions (4) of the housing part (2), and the at least one functional element is secured to a hub opening (9) at a thickened portion of the shaft (1). As part of the method, the functional elements are first inserted into the housing part (2), and the shaft (1) can then be inserted by means of a temperature difference. While the shaft (1) is being inserted, the functional elements are preferably not yet in their final axial position and are also generally not yet in their final alignment with respect to the rotational angle. The functional elements are then positioned into the correct position by means of a pressing process. According to the invention, at least one of the bearing receiving portions (4) is designed such that a rolling bearing (5) is inserted, in particular pressed, into a receiving opening (6) of the housing part (2) prior to inserting the shaft (1) into the housing part (2).