Wire Coupler Harmonic Drive Link for Camshaft Adjusters
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Solution Overview
Problem
Existing control devices for electromechanical camshaft adjusters lack a compact, production-friendly structure with high operational reliability, particularly in handling frequent changes in torque and direction between the motor shaft and control transmission.
Innovation Solution
A control device featuring a two-armed wire coupler with a winding around the motor shaft, providing a direct and secure connection without additional parts, capable of compensating for axial offsets and offering easy mounting and space-saving design, with optional backlash-free connection and elastic resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a central piece is used to connect the wire coupler to the motor shaft, then the connection can be established, but the structure becomes more complex and requires additional parts
Solution Approach 1:
The patent removes the central piece from the coupling mechanism, integrating its function directly into the motor shaft through a rectangular cross-section design. This extraction eliminates the need for separate mounting components while maintaining the connection functionality between the wire coupler and motor shaft.
Solution Approach 2:
The motor shaft is designed with a rectangular cross-section that directly receives the wire coupler, merging the mounting function into the shaft itself. This integration combines the shaft and mounting interface into a single component, reducing overall device complexity while facilitating easy assembly.
2Reliability
If a rigid connection is used between motor shaft and control transmission, then torque transmission is efficient, but the device cannot compensate for axial offsets
Solution Approach 1:
The wire coupler is constructed from spring wire that forms a flexible, two-armed structure capable of bending and deformation. This flexible wire structure compensates for axial offsets between the motor shaft and control transmission while maintaining reliable torque transmission through its elastic properties.
Solution Approach 2:
The wire coupler's physical parameters (shape, orientation, degree of bending) can dynamically change to accommodate axial offsets. The spring wire material allows the coupler to deform elastically, changing its geometric parameters to maintain connection despite misalignment while continuing to transmit torque effectively.
3Adaptability or versatility
If frequent torque changes occur between motor shaft and control transmission, then the device can adapt to varying loads, but connection loosening may occur
Solution Approach 1:
The rectangular cross-section of the motor shaft and the corresponding fit with the wire coupler create a form-fit connection that prevents loosening before it can occur. This geometric interlocking provides inherent stability against torque variations, cushioning against the harmful effect of connection loosening under frequent load changes.
4Reliability
If separate compensating elements are used, then axial offsets can be compensated, but the device size increases and structure becomes more complex
Solution Approach 1:
The wire coupler integrates multiple functions into a single component: it provides torque transmission, compensates for axial offsets through its flexible spring wire construction, and connects the motor shaft to the control transmission. This merging eliminates the need for separate compensating elements like Oldham disks, reducing component count while maintaining compensation capability.
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 ensures a robust, compact, and reliable connection that maintains operational stability even with varying torque conditions, reducing the need for separate compensating elements and allowing for efficient use in electromechanical camshaft adjusters and other applications like reciprocating piston engines.
Implementation Method 1
a two-armed wire coupler (7), in particular made of spring wire, is provided as the coupling element
Implementation Method 2
a winding (26) which is wound around the motor shaft (6) in a non-rotating manner
Data Source
AI summary
The disclosure relates to a control device, in particular in an electromechanical camshaft adjuster, comprising an electric motor and a control transmission coupled to the electric motor via a coupling element and designed as a harmonic drive. A two-armed wire coupler is provided as the coupling element, the arms of which engage in openings of an inner ring of a waveform generator of the control transmission, and the wire coupler has a winding which is wound around the motor shaft of the electric motor in a non-rotating manner.