Segmented Side Cover for Variable Valve Timing Weight Reduction
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Solution Overview
Problem
Existing apparatuses for variable setting of gas exchange valves in internal combustion engines have a complex and heavy side cover structure due to threaded regions, leading to increased weight and cost, and require expensive sintered components for strength.
Innovation Solution
The side cover is configured in multiple pieces with separately produced mating elements, allowing for a non-positive, positive, or material-to-material connection, enabling the use of lightweight materials and reducing weight by optimizing the structure for sealing and fastening, with options including screws, bolts, and clip connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the side cover is configured as a single integrated component with threaded regions, then structural strength is ensured, but the weight and manufacturing cost increase
Solution Approach 1:
The side cover is divided into two separate components: a sealing cover made from lightweight material (such as aluminum or plastic) and separate mating elements (such as threaded nuts or annular bodies) made from strong material. This segmentation allows each component to be optimized for its specific function - the sealing cover for weight reduction and the mating elements for structural strength - thereby resolving the contradiction between weight and strength requirements.
2Strength
If the side cover is configured as a single integrated component with threaded regions, then structural strength is ensured, but manufacturing complexity and cost increase
Solution Approach 1:
By separating the sealing cover from the mating elements, the design simplifies the sealing cover to its basic sealing function, which can be manufactured using simple processes like punching or deep drawing. The complex threaded or fastening functions are moved to separate mating elements, reducing the overall manufacturing complexity and cost while maintaining structural strength.
Solution Approach 2:
The threaded regions and fastening functions are extracted from the sealing cover and implemented as separate mating elements. This extraction allows the sealing cover to be manufactured as a simple thin-walled component without complex features, thereby reducing manufacturing complexity and cost while the separate mating elements provide the necessary structural strength.
3Strength
If different materials are used for fastening elements and mating elements, then structural requirements are met, but corrosion resistance deteriorates
Solution Approach 1:
The patent specifies that the fastening elements and mating elements should be made from the same material (such as both steel or both aluminum) to prevent galvanic corrosion. This homogeneity in material selection eliminates the electrochemical potential difference between dissimilar metals, thereby preventing corrosion while still meeting the structural strength requirements through proper material selection and design.
Data Source
AI summary
An apparatus for variable setting of control times of gas exchange valves of an internal combustion engine which has a drive element, an output element and a side cover. The drive element is brought into drive connection with a crankshaft, the output element is brought into drive connection with a camshaft, and the output element is arranged such that it can be pivoted with respect to the drive element. The side cover, which has a sealing cover with an opening and a mating element, axially delimits the output element and/or the drive element, and is connected in a rotationally fixed manner to the drive or output element by means of a fastening element. The fastening element reaches at least partially through the opening and interacts with the fastening element producing a rotationally fixed connection between the side cover and output element or drive element.