Variable-Undercut Camshaft Cam for Stable Forming
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Solution Overview
Problem
Existing camshaft designs for internal combustion engines lack effective production methods that enhance stability and operational variability, with prior methods involving constant undercuts and machining processes that are inefficient and require deburring.
Innovation Solution
A camshaft design featuring axially arranged part cams with variable running face contours and a non-circular undercut profile produced using forming technology, where the undercut contour depends on the radial spacing of the part cams, allowing for different closing behaviors and reduced material removal, thereby increasing stability and reducing production stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If constant circular undercuts are used in prior cam designs, then the structure is simple, but the production effectiveness and stability are insufficient
Solution Approach 1:
The patent applies asymmetry by replacing the traditional constant circular undercut with a variable non-circular undercut profile. The undercut contour varies along the axial direction, creating an asymmetric geometry that optimizes material distribution and stress characteristics during forming, thereby improving production effectiveness and stability.
Solution Approach 2:
The patent implements parameter changes by varying the undercut contour parameters along its length. Instead of maintaining a constant radius, the undercut profile changes its geometric parameters (radius, shape) in different axial positions, allowing optimization of the forming process and final cam stability.
2Ease of manufacture
If machining processes are used to produce undercuts, then the structure can be achieved, but the production process is inefficient and requires deburring
Solution Approach 1:
The patent replaces the mechanical machining system with a forming system. Instead of removing material through cutting and machining operations, the cam is produced by forming the final geometry directly from a blank using a forming die, which creates the undercut profile in a single operation without subsequent deburring.
Solution Approach 2:
The patent applies preliminary action by pre-shaping the blank and designing the forming die to create the final undercut geometry in advance. The forming process prepares the complete final structure including the variable undercut profile in one step, eliminating the need for subsequent machining and deburring operations.
3Adaptability or versatility
If part cams with different running face contours are provided, then operational variability is achieved, but production stability decreases
Solution Approach 1:
The patent applies universality by designing a single forming die that can produce multiple part cams with different running face contours. The die design allows for producing various cam profiles while maintaining consistent undercut geometry, enabling one tool to serve multiple functions and maintain production stability.
Solution Approach 2:
The patent implements local quality by differentiating only the necessary portions of the cam (the running face contours) while keeping the undercut profile uniform. This allows variation in the functional surfaces for different operational requirements while maintaining consistent critical geometry in the undercut region, balancing versatility with production stability.
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 design achieves higher stability and longer die service life, lower pressing forces, and varied cylinder operation without the need for deburring, enhancing production efficiency and operational performance.
Implementation Method 1
at least two part cams (1, 2) and an undercut (10, 20) which are situated in between, are produced using forming technology
Data Source
AI summary
A cam having at least two part cams are arranged axially behind one another along a longitudinal axis includes an undercut between the cam parts. The part cams have running faces which lie radially on the outside of the part cams and have different variable running face contours. The undercut has a profile with a variable contour which is dependent in each case on that adjacent running face contour which is at a smaller radial spacing from the longitudinal axis than the other running face contour.