Stamped Cranktrain Phase Adjuster for Low-Cost VCR Assembly
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Solution Overview
Problem
Existing variable compression ratio (VCR) adjustment systems for internal combustion engines are expensive due to the need for components formed via casting or machining, making them costly and less affordable for compact phase adjuster assemblies.
Innovation Solution
A phase adjuster assembly is designed with stamped components, including an input gear assembly, output gear assembly, drive plate, and support plate, along with a bearing assembly, to provide a cost-effective and compact solution for adjusting the phase between driving and driven components in a cranktrain, utilizing a method that includes a piston assembly and oil control valve assembly for hydraulic control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If components are formed via casting or machining, then manufacturing precision and strength are improved, but production cost increases
Solution Approach 1:
The patent applies this principle by using stamped components instead of expensive cast or machined parts. The stamped drive plate, support plate, and other components provide sufficient functionality at a fraction of the cost of traditional manufacturing methods, making the phase adjuster assembly economically viable for mass production in automotive applications.
Solution Approach 2:
The patent changes the manufacturing parameter from high-cost casting/machining to low-cost stamping. This parameter change maintains adequate manufacturing precision for the application while dramatically reducing production costs, enabling affordable implementation of variable compression ratio technology.
2Reliability
If traditional VCR adjustment systems are used, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent segments the phase adjuster assembly into distinct functional modules: input gear assembly, output gear assembly, drive plate with spline, support plate, and bearing assembly. This segmentation allows each component to be optimized independently and assembled through standardized connections, reducing overall system complexity while maintaining reliability.
Solution Approach 2:
The stamped drive plate serves multiple functions: it provides structural support, transmits torque through the spline connection, and enables phase adjustment. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly while maintaining system reliability.
Data Source
AI summary
A phase adjuster assembly configured to adjust a phase between a driving component and a driven component of an internal combustion engine is generally provided. The assembly includes an input gear assembly comprising an input gear configured to engage a driving component, and a spline carrier. An output gear assembly includes an output gear configured to engage a driven component, and a drive plate configured to drivingly engage with the spline carrier. Various components disclosed herein are formed as stamped sheet metal components. Additionally, various connections between adjacent components are provided via relative uncomplicated processes, such as welding.