Strain Wave Gear Push-In Tab Assembly for Compact Camshaft Adjusters
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Solution Overview
Problem
Existing strain wave gears for camshaft adjusters lack a compact and assembly-friendly design with low moments of inertia, often requiring additional fasteners for connection, which increases complexity and part count.
Innovation Solution
A strain wave gear design featuring a housing element with positive locking elements, such as push-in tabs, that securely connect the drive element without additional fasteners, allowing force and moment transmission while minimizing size and parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional fasteners (screws, locking rings, clamps) are used to connect the drive element to the housing element, then the connection strength and reliability are improved, but the device complexity and part count increase
Solution Approach 1:
The drive element is integrated directly with the housing element through positive locking elements that are formed as integral parts of the drive element itself. This merging eliminates the need for separate fasteners (screws, locking rings, or clamps) while maintaining a reliable connection that can transmit forces and moments between the drive element and housing element.
Solution Approach 2:
The connection function is extracted from separate fastener components and incorporated directly into the drive element structure. The positive locking elements are formed integrally with the drive element, removing the need for additional connecting parts while preserving the essential function of transmitting forces and moments.
2Device complexity
If a compact design with fewer parts is used to reduce device complexity, then assembly-friendliness and low moments of inertia are improved, but the connection strength between drive element and housing element may worsen
Solution Approach 1:
The drive element and housing element are merged through integral positive locking elements that provide both structural strength and connection functionality. This integration maintains connection strength while reducing part count, as the locking elements are formed as part of the drive element rather than requiring separate fasteners.
Solution Approach 2:
The positive locking elements utilize composite structural design combining rigid mounting portions with flexible locking portions. This allows the connection to maintain strength for force and moment transmission while the flexible portions enable assembly through elastic deformation, achieving both strength and ease of assembly.
3Ease of operation
If positive locking elements are designed as push-in tabs extending in the axial direction, then assembly-friendliness is improved, but the number of tabs required for sufficient locking may increase device complexity
Solution Approach 1:
The positive locking elements exhibit local quality differentiation with rigid portions for structural support and force transmission, and flexible portions for engagement and locking. This local differentiation allows each tab to perform multiple functions (structural support, elastic deformation for assembly, and positive locking) reducing the total number of elements needed.
Solution Approach 2:
The push-in tabs are designed as multi-functional elements that simultaneously provide structural support, enable elastic deformation for assembly, and create positive locking engagement. This universality allows a small number of tabs to perform multiple functions that would otherwise require separate components.
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
The solution provides a compact, assembly-friendly strain wave gear with reduced moments of inertia and eliminated fasteners, enhancing reliability and efficiency in applications like electromechanical camshaft adjusters and piston engine compression ratio variation.
Implementation Method 1
an elastic, externally toothed gear element (34)
Data Source
AI summary
A strain wave gear, in particular for an electromechanical camshaft adjuster, comprises a housing element, an internally toothed drive element connected thereto in a rotationally fixed manner, an elastic, externally toothed gear element, and an internally toothed output element. The drive element has positive locking elements with which it is connected to the housing element.