DE102012205705B4 - Camshaft adjuster with a front and / or output element in sandwich construction and a method for producing the input or output element in sandwich construction - Google Patents

Abstract

Camshaft adjuster (1) with - a drive element (2) and an output element (3), - wherein the drive element (2) and the output element (3) are coaxial with the axis of rotation (4) of the camshaft adjuster (1) and rotatable relative to each other, - wherein the drive element (2) and the driven element (3) each have a plurality of wings (9), characterized in that the arrival and / or the driven element (2, 3) comprises a framework (7), which consists of several, axially spaced and stacked arranged metal parts (5a, 5b) and one or more spacers (6a, 6b, 6c, 6d, 6e) is constructed, wherein the spacer or spacers (6a, 6b, 6c, 6d, 6e) has a gap (8 ) between the spaced and stacked metal parts (5a, 5b), said gap (8) being filled by a filler (18), thereby forming a solid composite of filler (18) and framework (7) and thus the Antrieb- and / or the output element (2, 3) is formed in sandwich construction.

Description

Field of the invention

The invention relates to a camshaft adjuster with a front and / or output element in sandwich construction and a method for producing the input or output element in sandwich construction.

Background of the invention

Camshaft adjusters are used in internal combustion engines for varying the timing of the combustion chamber valves in order to make the phase relation between a crankshaft and a camshaft in a defined angular range, between a maximum early and a maximum late position, variable. Adjusting the timing to the current load and speed reduces fuel consumption and emissions. For this purpose, camshaft adjuster are integrated into a drive train, via which a torque is transmitted from the crankshaft to the camshaft. This drive train may be formed for example as a belt, chain or gear drive.

In a hydraulic camshaft adjuster, the output element and the drive element form one or more pairs of mutually acting pressure chambers, which can be acted upon by hydraulic fluid. The drive element and the output element are arranged coaxially. By filling and emptying individual pressure chambers, a relative movement between the drive element and the output element is generated. The rotationally acting on between the drive element and the output element spring urges the drive element relative to the output element in an advantageous direction. This advantage direction can be the same or opposite to the direction of rotation.

One type of hydraulic phaser is the vane phaser. The vane cell adjuster comprises a stator, a rotor and a drive wheel with an external toothing. The rotor is designed as a driven element usually rotatably connected to the camshaft. The drive element includes the stator and the drive wheel. The stator and the drive wheel are rotatably connected to each other or alternatively formed integrally with each other. The rotor is coaxial with the stator and located inside the stator. The rotor and the stator are characterized by their, radially extending wings, oppositely acting oil chambers, which are acted upon by oil pressure and allow relative rotation between the stator and the rotor. The wings are either formed integrally with the rotor or the stator or arranged as "inserted wings" in designated grooves of the rotor or the stator. Furthermore, the vane cell adjusters have various sealing lids. The stator and the sealing lids are secured together via several screw connections.

Another type of hydraulic phaser is the axial piston phaser. In this case, a displacement element is axially displaced via oil pressure, which generates a helical gear teeth relative rotation between a drive element and an output element.

Another design of a camshaft adjuster is the electromechanical camshaft adjuster, which has a three-shaft gear (for example, a planetary gear). One of the shafts forms the drive element and a second shaft forms the output element. About the third wave, the system by means of an adjusting device, such as an electric motor or a brake, rotational energy supplied or removed from the system. A spring may additionally be arranged, which supports or returns the relative rotation between the drive element and output element.

The DE 103 58 888 A1 shows an internal combustion engine with a hydraulic device for adjusting the rotational angle of a camshaft relative to a crankshaft, comprising: a rotor with wings arranged therein, which is non-rotatably connected to the camshaft, a frontally provided with an end wall, tubular stator, the rotationally fixed to a crankshaft driven Drive wheel is connected, wherein on both sides of the wing pressure chambers are provided which are each bounded by web walls and walls extending in the circumferential direction of the stator and can be filled and emptied via a hydraulic system with hydraulic fluid. A reduction in the weight of the device on the other hand while minimizing the leakage is achieved by the fact that the stator including its radially extending web walls and circumferentially extending walls and / or the housing are made with an optional sealing disc or without cutting.

Summary of the invention

The object of the invention is to provide a camshaft adjuster, which has a particularly low weight and high wear resistance and high rigidity.

According to the invention this object is achieved by the features of claim 1 and by a method according to claim 13.

The object is achieved by a camshaft adjuster having a drive element and an output element, wherein the drive element and the driven element are arranged coaxially to the axis of rotation of the camshaft adjuster and rotatable relative to each other, wherein the drive element and the driven element each have a plurality of wings, inventively achieved that the and / or the output member comprises a framework composed of a plurality of axially spaced and stacked metal members and one or more spacers, the spacer defining a space between the spaced and stacked metal members this gap of a filler, in particular a material different from the material of the metal parts, is materially filled.

As a result, a composite and thus an input and / or output element is formed in sandwich construction, whereby its weight is significantly reduced and at the same time wear-resistant functional surfaces are formed of metal. Another advantage is that wear and friction is minimized and life is increased.

In sandwich construction, the abovementioned metal parts alternate with the filler in the axial direction. It makes sense to at least two metal parts are necessary. The filler may be at least two metal parts on the one hand exclusively in between or on the other flank the metal parts on both axial sides.

By forming a framework of a plurality of axially spaced apart and layered arranged metal parts, which are held by spacers to the desired distance from each other, a support body or a core is made. The metal parts are advantageously disc-shaped. The framework can be assembled in a first step from the individual parts (metal parts and spacers), optionally additionally in a second step to ensure stability, the items (metal parts and spacers) are held together by fabric, force or form-fitting connections. Welding, in particular punctiform welding, gluing or soldering, is suitable as cohesive connections. As a non-positive connection, a press fit between the individual parts (metal parts and spacers) offers. For a positive connection of the individual parts (metal parts and spacers), the items may be provided with grooves or recesses into which engage corresponding engagement elements of the counterpart. For example, the spacers may have a plurality of spaced-apart grooves, in which engage the metal parts, which is defined with the predefined distance of the grooves of the distance of the metal parts to each other. Advantageously, by securing the individual parts (metal parts and spacers), the framework is stabilized during handling, so that it does not disintegrate before the introduction of the filler.

The spacers may be formed as clamps or buckles to space the metal parts apart from one another and to hold the framework together.

The existing framework is filled with the filler in a third step, so that at least the axial spacings of the metal parts are provided with filler. In the subsequent step, a solid composite and thus the input and / or output element in sandwich construction is produced by the curing of the filler. If necessary, post-processing can finally be carried out.

The introduction of the filler, for example. Of a plastic or a light metal, between the metal parts can be done by casting, in particular injection molding. Obviously, the filler should have a liquid state for introduction. Alternatively, the filler may be present as a powder and introduced in this initial form between the metal parts. Optionally, under the imposition of pressure on the composite, the blank can be baked under heat, so that a solid composite and thus the input and / or output element is in sandwich construction.

As already mentioned, the filler does not only have to fill only the intermediate spaces between the metal parts, but can also enclose or encase the metal parts in addition. The outer shape for forming the characteristics of the input and / or output element is thus imaged by a casting or sintering process tool. The wrapping of the metal parts with the filler, preferably plastic, advantageously protects the metal parts in the core of the composite against corrosion and damage, in particular in the uninstalled state of the input and / or output element in the camshaft adjuster.

Another advantage of the invention of the formation of the input and / or output element in sandwich construction described above is in addition to the reduction of weight, the reduction of noise. By choosing the filler as a different material from the metal parts, the propagation through structure-borne noise can be minimized. This effect is reinforced by the targeted introduction of an amorphous structure of the filler, in particular when plastic is preferably used as filler or the filler has been baked by sintering with the metal parts.

The spacers are transversely, ideally orthogonal or at least angled, arranged to the metal parts and keep the metal parts at a distance from each other. For this purpose, one or more spacers can be located exactly between two metal parts and be supported on the surfaces facing the gap.

Alternatively, one or all of the spacers partially penetrate at least one of the metal parts and thus keep at a distance.

Alternatively, one or all of the spacers engage around or penetrate at least one of the spaced-apart metal parts, so that at least one or all spacers protrude on the side of the metal parts facing away from the intermediate space or terminate flush with the surface of the metal part facing away from the intermediate space.

In an advantageous embodiment of the invention, the spacers are integrally formed by the metal parts. Advantageously, the number of components to be joined is minimized and reduces the effort to stabilize the framework for mounting.

In one embodiment of the invention, the or the spacers are designed as bearing shoes of the input and / or output element. The bearing shoes designed as spacers are arranged on the boundary wall of the metal parts facing the component to be accommodated or to be supported. Bearing forces can thus advantageously by the spacers, which are preferably formed as the metal parts made of metal, are transferred directly to the core forming metal parts, without burdening the filler.

In an advantageous embodiment, the bearing shoes are arranged at the radial ends of the wings and store the wings. The bearing shoes are either formed by one end of the wings of the respective input and / or output element itself or placed as a separate component on the wing.

If the bearing shoes, for example, at the inner radial end of the wings of the drive element in one piece or arranged as an additional component, the output element is supported on the outer peripheral surface of its hub of these bearing shoes and guided in the direction of rotation.

Alternatively or additionally, the wings of the output element may have the bearing shoes. On the one hand, the radially outer ends of the wings of the output element may have the bearing shoes. On the other hand, in the case of inserted wings, the receptacles of the inserted wings on the output element have the bearing shoes.

In a particularly preferred embodiment, the bearing shoes protrude in the radial direction. Due to the protruding out of the composite of metal parts and filler, the bearing surface of the bearing shoes is advantageously delimited from the rest of the material of the composite and spared from minimally occurring wear for a longer service life. The radial abrasion through wear can thus be maintained by the radial projection.

In a preferred embodiment, a gap is provided between the bearing shoes and the framework in the radial direction. A festmaterialfreier gap advantageously has good damping properties in the event of imbalance or concentricity errors. Optionally, the gap can be provided with damping material.

In one embodiment of the invention, a bearing shoe is integrally formed by a metal part. Advantageously, such a highly integrated formation of the framework is made possible. Sheet metal material is preferably used, which is formed by forming process into a framework.

In an advantageous embodiment, the metal parts and the wings are integrally formed, wherein in the region of the wings an axially oriented recess is arranged. This axial recess can be penetrated by the filler or be, so as to support and secure the composite of metal parts both in the circumferential direction and in the axial or radial direction. According to the case that the axial recess is provided on its inner circumferential surface with a layer of the filler, the free space of the axial recess for receiving a fastening means, for example. A fastening screw can be used. The fastening means rotatably connect the axially adjacent components of the camshaft adjuster, in particular those from which the drive element is formed.

In a particularly preferred embodiment, at least one of the axially spaced apart metal parts protrudes circumferentially from a wing to form a stop for a complementary wing. Advantageously, such a solid, metallic stop is given, which is resistant to wear.

In a particularly preferred embodiment of the invention, the metal parts are thin-walled sheet-metal parts. The shape of the metal parts can be stamped. Preferably, the metal parts are as plates formed with plane-parallel faces. Alternatively, the metal parts formed as plates may have corrugations or ribs in order to reinforce their stability and that of the framework as well as of the finished composite.

Preferably, the spacers may also be formed as a thin-walled sheet metal part. The shape of the spacers can be punched. The spacers can be bent over by further forming processes, whereby, for example, the functional surface of the bearing is formed. The spacers and the metal parts may advantageously have been exposed independently of different heat treatments.

Alternatively, the spacers may be integrally formed by the metal parts. In particular, in a formation of sheet metal, it is advantageous to provide a integrally formed with the metal part and projecting tab as a spacer.

In a preferred embodiment of the invention, the filler is a non-metal or a light metal. As non-metal, plastics are used. As a light metal, however, the density of the light metal itself or as a filler should be less than the density of the metal parts and / or spacers from which the framework is formed.

The inventive construction of a scaffold, which is constructed of spaced-apart metal parts and spacers, a filler is introduced by the filling of the spaces between the metal parts and the spacers and thus achieved a lightweight yet stable arrival and / or output element in sandwich construction.

Brief description of the drawings

Embodiments of the invention are illustrated in the figures.

Show it:

1 a phaser of the prior art,

2 an inventive drive element in a perspective view,

3 a section through the drive element according to the invention 2 .

4 another, to cut 3 orthogonal section through the drive element according to the invention and

5 a bearing shoe with an integrally formed thereon spacers of the drive element according to the invention 2 ,

Detailed description of the drawings

In 1 is an example of a hydraulic camshaft adjuster 1 shown in vane-type construction of the prior art in a front view with a clear view of his interior, which is a drive element 2 and an output element 3 each having several wings 9 train, with the wings 9 Divide working chamber A, B acting in opposite directions and the working chambers A, B can be pressurized with hydraulic fluid to a relative rotation about the axis of rotation 4 of the camshaft adjuster 1 between the drive element 2 and the output element 3 to reach. The hydraulic fluid is the working chamber A, B via hydraulic fluid channels 15 . 16 each added or removed. The drive element 2 has a rotatably arranged toothing 14 , In this example is the gearing 14 for a not further shown, known from the prior art, chain drive suitable and integral with the drive element 2 educated. The drive element 2 is usually composed of several components, for example. A cover element, not shown here, constructed, wherein the components together to produce the component composite by the screws 17 are tightly clamped. The output element 3 can be rotatably connected to a camshaft, not shown. Due to the relative rotation of the drive element 2 to the output element 3 is thus a change in the timing on the adjustment of the phase angle between a crankshaft and the camshaft achievable. The basic structure and function of such a camshaft adjuster 1 is well known. In the following, the specific features and details of this exemplary embodiment will be discussed.

2 shows an inventive drive element 2 in a perspective view. The drive element 2 has five wings 9 which extend inward in the radial direction. At each radially inner end of a wing 9 each is a bearing shoe 10 arranged. The scaffolding 7 , which consists of two axially spaced metal parts 5a . 5b and five camp shoes 10 consists of each of the five bearing shoes 10 in each case a spacer according to the invention 6a - 6e has almost completely of the filler 18 jacketed. In 5 becomes a bearing shoe 10 with his spacer 6a shown and described in more detail, since in this 2 the view of the spacers 6a - 6e is denied. Only a large part of the bearing shoes 10 and part of, as a stop 13 trained, metal parts 5a and 5b are next to the filler 18 self-visible. The attacks 13 stick out of each wing 9 in the circumferential direction of the filler 18 out. Every wing 9 has a recess formed as a passage opening 11 on, which in the axial direction, parallel to the axis of rotation 4 , is oriented. The recesses 11 be used for assembly with other components and thus to complete the camshaft adjuster 1 of screws 7 projects through. Between each bearing shoe 10 and his wing 9 is a gap 12 intended. Advantageously, the bearing shoe 10 in this gap 12 to dodge, whereby a damping bearing is formed. Every bearing shoe 10 is in the filler 18 firmly anchored. The intended training of each bearing shoe 10 is with 5 described. The bearing shoes 10 extend completely and continuously from one end face to the other end face of the drive element 2 ,

3 shows a section through the drive element according to the invention 2 to 2 , Clearly visible are the two axially spaced apart, arranged parallel to each other and orthogonal to the axis of rotation 4 arranged metal parts 5a and 5b , The metal parts 5a and 5b are part of the scaffold 7 , The axial gap 8th between the flat and disc-like metal parts 5a and 5b is with filler 18 completely filled up. The filler 18 encased in this cross-section of the metal parts 5a and 5b and additionally extends in the axial direction of the space 8th opposite sides of the metal parts 5a and 5b and form end faces of the drive element 2 from which the drive element 2 limit in the axial direction. Also clearly visible is the gap 12 between the radial end of the wing 9 and the bearing shoe 10 , The gap 12 also extends from an end face of the drive element 2 to his other end. Striking is that the metal parts 5a and 5b are arranged eccentrically between the end faces, which advantageously z. B. the center of gravity closer to the camshaft facing side of the camshaft adjuster 1 can be positioned and so by the weight of the camshaft adjuster 1 caused bending moment can be reduced at the camshaft end. It is conceivable, especially in this view, that the metal parts 5a and 5b a gearing 14 can, which from the outer periphery of the drive element 2 protrudes and can be brought into engagement with a traction device.

4 shows another, cut to 3 orthogonal section through the drive element according to the invention 2 , The section is along the section line XX from the 3 educated. The outer circumference 22 of the drive element 2 is the same as the inner surface of the recesses 11 completely from the filler 18 surround. Well recognizable is the shape of the metal part 5a which are both the one-piece wings 9 , as well as the attacks 13 having. The radial boundary walls 23 the with the output element 3 formable working chambers A and B are also on the inside with the filler 18 afflicted. Likewise, every wing is 9 at its radial inner end with the filler 18 Afflicted, but from the bearing shoe 10 protrudes and with the filler 18 a gap 12 formed.

5 shows a bearing shoe 10 with a spacer formed integrally thereon 6 the drive element according to the invention 2 to 2 , The bearing shoe 10 is U-shaped, with the protruding legs 21 angled towards each other. The bearing shoe 10 points to each leg 21 two grooves 19 whose width of the material thickness of the respective metal part 5a respectively. 5b equivalent. The grooves 19 embrace the formation of the framework 7 the metal parts 5a and 5b , Between two grooves 19 of every thigh 21 is a tab 20 separated, which as a spacer 6a is formed to the gap 8th of the scaffolding 7 define. Every bearing shoe 10 of the 2 - 4 is designed the same shape and thus have the five bearing shoes 10 the spacers 6a . 6b . 6c . 6d and 6e for the axial spacing of the metal parts 5a and 5b on.

LIST OF REFERENCE NUMBERS

1

Phaser

2

driving element

3

output element

4

axis of rotation

5a

metal part

5b

metal part

6a

spacer

6b

spacer

6c

spacer

6d

spacer

6e

spacer

7

framework

8th

gap

9

wing

10

bearing shoe

11

recess

12

gap

13

attack

14

gearing

15

Hydraulic fluid channel

16

Hydraulic fluid channel

17

screw

18

filler

19

groove

20

flap

21

leg

22

outer periphery

23

radial boundary wall

A

working chamber

B

working chamber

Claims (17)

Camshaft adjuster ( 1 ) with - a drive element ( 2 ) and an output element ( 3 ), - wherein the drive element ( 2 ) and the output element ( 3 ) coaxial with the axis of rotation ( 4 ) of the camshaft adjuster ( 1 ) and are arranged rotatable relative to each other, - wherein the drive element ( 2 ) and the output element ( 3 ) several wings ( 9 ), characterized in that the input and / or the output element ( 2 . 3 ) a framework ( 7 ), which consists of a plurality of axially spaced apart and layered arranged metal parts ( 5a . 5b ) and one or more spacers ( 6a . 6b . 6c . 6d . 6e ), wherein the spacer (s) ( 6a . 6b . 6c . 6d . 6e ) a gap ( 8th ) between the spaced apart and layered metal parts ( 5a . 5b ), whereby this space ( 8th ) of a filler ( 18 ) is materially filled, whereby a solid composite of filler ( 18 ) and scaffolding ( 7 ) and thus the input and / or the output element ( 2 . 3 ) is designed in sandwich construction. Camshaft adjuster ( 1 ) According to claim 1, characterized in that the or the spacers ( 6a . 6b . 6c . 6d . 6e ) in one piece from the axially spaced apart metal parts ( 5a . 5b ) are formed. Camshaft adjuster ( 1 ) according to claim 1 or 2, characterized in that the spacer (s) ( 6a . 6b . 6c . 6d . 6e ) as bearing shoes ( 10 ) of the input and / or output element ( 2 . 3 ) are formed. Camshaft adjuster ( 1 ) according to claim 3, characterized in that the bearing shoes ( 10 ) at the radial ends ( 14 ) the wing ( 9 ) are arranged and the wings ( 9 ) to store. Camshaft adjuster ( 1 ) according to claim 3 or 4, characterized in that the bearing shoes ( 10 ) protrude in the radial direction. Camshaft adjuster ( 1 ) according to claim 5, characterized in that between the bearing shoes ( 10 ) and the framework ( 7 ) in the radial direction a gap ( 12 ) is provided. Camshaft adjuster ( 1 ) According to claim 1, characterized in that a bearing shoe ( 10 ) in one piece from a metal part ( 5a . 5b ) is trained. Camshaft adjuster ( 1 ) according to one of the preceding claims, characterized in that the metal parts ( 5a . 5b ) and the wings ( 9 ) are formed in one piece and in the area of the wings ( 9 ) an axially oriented recess ( 11 ) exhibit. Camshaft adjuster ( 1 ) according to one of the preceding claims, characterized in that the metal parts ( 5a . 5b ), except for the functional surfaces, which can be brought into contact with a peripheral component, completely from the filler ( 18 ) are sheathed. Camshaft adjuster ( 1 ) according to one of the preceding claims, characterized in that at least one of the axially spaced apart metal parts ( 5a . 5b ) in the circumferential direction of a wing ( 9 ) to detect a stop ( 13 ) for a complementary wing. Camshaft adjuster ( 1 ) according to one of the preceding claims, characterized in that the metal parts ( 5a . 5b ) are thin-walled sheet metal parts. Camshaft adjuster ( 1 ) according to any one of claims 1-8, characterized in that the filler is a non-metal or a light metal. Method for producing an input and / or output element ( 2 . 3 ) of the camshaft adjuster ( 1 ) according to the preamble of claim 1, marked by: - construction of a scaffolding ( 7 ) With - a plurality of metal parts spaced apart from one another and arranged in layers ( 5a . 5b ) and - one or more spacers ( 6a . 6b . 6c . 6d . 6e ) - wherein the spacer (s) ( 6a . 6b . 6c . 6d . 6e ) a gap ( 8th ) between the spaced apart and layered metal parts ( 5a . 5b ) define or define, then - filling the gap ( 8th ) with a filler ( 18 ), so that a solid composite from the framework ( 7 ) and the filler ( 18 ) and thus the input and / or the output element ( 2 . 3 ) is designed in sandwich construction. A method according to claim 13, characterized in that the filling of the intermediate space ( 8th ) by injection molding. A method according to claim 13, characterized in that the filling of the intermediate space ( 8th ) with a filler ( 18 ) is made in powder form and the solid composite is produced by a subsequent heat treatment. Method according to one of claims 13-14, characterized in that the spacers ( 6a . 6b . 6c . 6d . 6e ) are removed after making the solid composite. Method according to one of claims 13-16, characterized in that after the completion of the composite of scaffold ( 7 ) and filler ( 18 ) Bearing shoes ( 10 ) on the wings ( 9 ) are attached.

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