METHOD FOR JOINING A FUNCTIONAL MODULE, AND FUNCTIONAL MODULE

Abstract

A method of joining a functional module comprises the steps of providing a frame structure that defines a bearing channel with at least one circumferentially closed bearing seat; providing at least two attachment parts; providing a hollow shaft that comprises at least one support section for the at least two attachment parts, wherein the attachment parts comprise a mounting seat that is adapted to a support section; feeding the attachment parts in the bearing channel in a first feeding direction; feeding the hollow shaft in the bearing channel in a second feeding direction, wherein the hollow shaft is inserted into the respective mounting seat of the at least two attachment parts; and, subsequent to the feeding of the attachment parts and the hollow shaft in the bearing channel, at least sectionally widening the hollow shaft for a torsionally rigid fixation of the at least two attachment parts with their mounting seats at the respective support section of the hollow shaft.

Claims

1. A method of manufacturing a camshaft module comprising a housing that defines a bearing channel, and an assembled composite shaft that comprises a hollow shaft and cams that are fixed thereto in a torque-proof manner, wherein the composite shaft is mounted to the housing, wherein the method comprises the following steps: providing a housing that defines a bearing channel having at least one circumferentially closed bearing seat, providing a plurality of cams, providing a hollow shaft that comprises a plurality of support sections for the cams, wherein the cams each comprise a mounting seat that is adapted to a respective support section, feeding the cams in the bearing channel in a first feeding direction, feeding the hollow shaft in the bearing channel in a second feeding direction that is different from the first feeding direction, wherein the hollow shaft is inserted in the mounting seats of the cams, and subsequent to the feeding of the attachment parts and the hollow shaft into the bearing channel, at least sectionally widening the hollow shaft for fixing the cams with their mounting seat at the support sections of the hollow shaft in a torsionally rigid manner, wherein the hollow shaft is plastically deformed in the region of the support sections, and wherein the cams are elastically deformed.

2. The method as claimed in claim 1, wherein the cams, prior to the widening of the hollow shaft, are finished at their outer contour by means of material removing machining processes and provided with a shape that is defined in consideration of the elastic deformation that remains subsequent to the widening of the hollow shaft.

3. A method of manufacturing a functional module comprising a frame structure that defines a bearing channel and an assembled composite shaft that comprises a hollow shaft and attachment parts that are fixed thereto in a torque-proof manner, wherein the composite shaft is mounted at a frame structure, wherein the method comprises the following steps: providing a frame structure that is arranged as one of a bearing frame and a housing, and that defines a bearing channel having at least one circumferentially closed bearing seat, providing at least two attachment parts, providing a hollow shaft that comprises at least two support sections for the at least two attachment parts, wherein the at least two attachment parts each comprise a mounting seat that is adapted to a respective support section, feeding the at least two attachment parts in the bearing channel in a first feeding direction, feeding the hollow shaft in the bearing channel in a second feeding direction that is different from the first feeding direction, wherein the hollow shaft is inserted in the mounting seats of the at least two attachment parts, and subsequent to the feeding of the attachment parts and the hollow shaft into the bearing channel, at least sectionally widening the hollow shaft for fixing the at least two attachment parts with their mounting seat at the respective support section of the hollow shaft in a torsionally rigid manner, wherein the hollow shaft is plastically deformed in the region of the support sections, and wherein the at least two attachment parts are elastically deformed.

4. The method as claimed in claim 3, wherein the elastically deformed attachment parts, subsequent to the widening of the hollow shaft, comprise a final contour having an outer circumference having an actual dimension that corresponds to a functionally specified target dimension of the outer circumference.

5. The method as claimed in claim 3, wherein, subsequent to the widening of the hollow shaft, a final contour that is free from post-processing is present at the at least two attachment parts.

6. The method as claimed in claim 3, wherein subsequent to the widening of the hollow shaft, the at least two attachment parts are pressed in with their support sections under preloading, wherein the at least two attachment parts, prior to the widening of the hollow shaft, comprise an outer contour that is smaller than a functionally specified target outer contour, and wherein the at least two attachment parts, subsequent to the widening of the hollow shaft, comprise an actual outer contour that corresponds to the functionally specified target outer contour.

7. The method as claimed in claim 3, wherein at least some of the at least two attachment parts, prior to the widening of the hollow shaft, are provided at their outer contour with functional surfaces that are arranged as finished circumferential running surfaces.

8. The method as claimed in claim 3, wherein the at least two attachment parts, prior to the widening of the hollow shaft, are finished at their outer contour by means of material removing machining processes, and provided with a shape that is defined in consideration of the elastic deformation that remains subsequent to the widening of the hollow shaft.

9. The method as claimed in claim 3, wherein the step of feeding the attachment parts further comprises the following: aligning the at least two attachment parts, wherein the at least two attachment parts are arranged in a target joining orientation that determines a relative orientation of the at least two attachment parts with respect to one another that deviates from a target orientation of the attachment parts to one another in the joined state.

10. The method as claimed in claim 9, further comprising, subsequent to the feeding of the hollow shaft in the bearing channel: axially positioning the hollow shaft, adjusting the angular position of the hollow shaft relative to a first attachment part of the at least two attachment parts, and sectionally widening the hollow shaft for a torsionally rigid fixation of the first attachment part at a corresponding support section of the hollow shaft.

11. The method as claimed in claim 10, further comprising sequentially executing the following steps for a plurality of attachment parts: adjusting the angular position of the hollow shaft relative to a further one of the at least two attachment parts, and widening a further corresponding support section of the hollow shaft for a torsionally rigid fixation of the further attachment part, wherein by means of the sequential adjusting and widening, a desired relative angular orientation between the first attachment part and the further attachment part is achieved.

12. The method as claimed in claim 3 wherein the functional module is formed as an engine module, wherein the composite shaft is arranged as one of a control shaft and a cam shaft, and wherein the at least two attachment parts are selected from the group consisting of cam, flanges, bearing bushings, pulse generators, gear wheels, spacer sleeves, and sprockets.

13. The method as claimed in claim 3, further comprising, prior to the feeding of the at least two attachment parts and the hollow shaft, machining at least one of a support section of the hollow shaft and an associated mounting seat of an attachment part for forming a defined assembly clearance between the hollow shaft and the attachment part.

14. The method as claimed in claim 13, further comprising, prior to the feeding the hollow shaft, finishing machining at least one bearing section of the hollow shaft that is mounted to a bearing seat of the bearing channel in an assembled state.

15. The method as claimed in claim 14, further comprising assembling at least one bearing element that enables a relative rotation between the hollow shaft and the frame structure, comprising arranging the at least one bearing element between a bearing section of the hollow shaft and an associated bearing seat of the bearing channel.

16. The method as claimed in claim 3, wherein the step of widening the hollow shaft further comprises: inserting a lance shaped or mandrel shaped deformation tool into the hollow shaft, and sequentially or simultaneously widening a plurality of support sections of the hollow shaft, that are associated with respective attachment parts to be joined.

17. The method as claimed in claim 16, wherein the widening of at least one support section is performed without counter-holding by means of an outer die.

18. A functional module, comprising a frame structure that defines at least one bearing channel, and at least one assembled composite shaft that is mounted to the frame structure and that comprises a hollow shaft and attachment parts that are fixed thereto in a torque-proof manner, wherein the frame structure comprises a radially closed bearing channel, wherein the attachment parts comprise mounting seats that are adapted to respective support sections of the hollow shaft, wherein the support sections of the hollow shaft are widened to fix the associated attachment parts torsionally rigid to the hollow shaft, wherein the hollow shaft, in the region of its support sections, is plastically deformed, and wherein the attachment parts are elastically deformed and pressed in with their support sections.

19. The functional module as claimed in claim 18, wherein the bearing channel is radially inaccessible for a hollow shaft.

20. The functional module according to claim 19, wherein the bearing channel for the assembled composite shaft is axially inaccessible for the attachment parts, wherein at least one bearing element is provided that couples a bearing section of the hollow shaft and an associated bearing seat of the frame structure to one another, and wherein the bearing element is arranged between two adjacent widened support sections, each of which supports an attachment part in a torque-proof manner.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0102] Further features and advantages of the disclosure are disclosed by the following description of a plurality of exemplary embodiments, with reference to the drawings, wherein:

[0103] FIG. 1 is a perspective view of an assembled composite shaft that is arranged as a cam shaft;

[0104] FIG. 2 is a schematic exploded view of the cam shaft according to FIG. 1;

[0105] FIG. 3 is a perspective simplified view of a housing that is for instance arranged as a cam shaft housing, and that accommodates two cam shafts;

[0106] FIG. 4 is a simplified perspective view of a bearing frame at which two cam shafts are mounted;

[0107] FIG. 5 is a perspective view of a bearing frame that is not equipped, based on the arrangement of the bearing frame according to FIG. 4;

[0108] FIG. 6 is a simplified schematic plan of an assembled composite shaft that is arranged as a cam shaft, and that is mounted at a frame structure, during a joining procedure;

[0109] FIG. 7 is a side view of the cam shaft according to FIG. 6, wherein the illustration of the frame structure is omitted, and wherein a deformation state is shown in an out-of-engagement position;

[0110] FIG. 8 is a simplified schematic partial view of a to-be-joint assembly of a hollow shaft and an attachment part in a non-joint state;

[0111] FIG. 9 is a cross-sectional view of a hollow shaft that is to be joined with an attachment part, similar to the view of FIG. 8, wherein a deformation tool is inserted into the hollow shaft to widen a support section of the hollow shaft;

[0112] FIGS. 10, 11, 12 and 13 schematic, greatly simplified perspective views of a composite shaft that is arranged as a cam shaft, for elucidating aspects of an exemplary joining procedure, and

[0113] FIG. 14 is a schematic block view of an exemplary arrangement of a method for joining a functional module in accordance with at least some principles of the present disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0114] With reference to FIGS. 1, 2 and 3 an exemplary arrangement of an assembled shaft 10 which may be arranged as a cam shaft 12, for instance, will be elucidated. As already mentioned herein before, the shaft may also be referred to as composite shaft 10. In addition to cam shafts 12, also other shafts that may be used in combustion engines may be arranged as assembled composite shafts 10. Hereinafter, the unified term cam shaft 12 will be used, however, this shall not be construed to be limiting.

[0115] The cam shaft 12 comprises a pre-product which may also be referred to as support shaft 14. In some embodiments, the support shaft 14 may be arranged as a hollow shaft 16. The hollow shaft 16 is at least sectionally provided with a hollow profile 18, for instance continuously along its entire longitudinal extension. In the following, the term hollow shaft 16 will be used uniformly which is, however not to be construed to be limiting.

[0116] The cam shaft 12 is shown in FIG. 1 in an assembled, joined state, and in FIG. 2 in an exploded state. At the hollow shaft 16, a plurality of attachment parts 20 is arranged, refer to FIG. 1. The attachment parts 16 may involve, for instance, cams 22, gear wheels 24 (refer particularly to FIG. 3), sleeves 26, bearings or bearing rings 28, flanges 30 and such like. For a better understanding, in the following, primarily the term cams 22 will be used, even though the attachment parts 20 may basically involve also other components. At least some of the attachment parts 20, for instance the cams 22 and the gear wheels 24, have to be fixed to the hollow shaft 16 so tightly that a reliable torque transmission is enabled. A relative rotation between the cams 22 and/or the gear wheels 24 and their hollow shaft 16 has to be preempted with a high degree of certainty. The cams 22 comprise functional surfaces in the shape of circumferential running surfaces 32 that are commonly precision-machined.

[0117] It is basically known in the prior art to join cams 22 and similar attachment parts by means of so-called internal high pressure forming methods (hydroforming-methods) with hollow shafts 16 to form assembled cam shafts 12. In this context, reference is again made to US Publication No. 2003/0150095 and the procedure of the method basically described therein and the devices basically described therein.

[0118] A further trend in manufacturing technology, for instance for the manufacture of modular assemblies or functional modules for combustion engines relates to an integral manufacture, if possible, of housing components, frame structures and similar, to avoid thoughtful machining processes and/or assembly processes. In this context, by way of example, FIGS. 3 and 4 illustrate functional modules 40 that comprise integrally shaped frame structures 42. As used herein in the present disclosure, for instance a housing 44 (refer to FIG. 3), a bearing frame 46 (refer to FIG. 4 and FIG. 5) and similar structural elements for accommodating cam shafts 12 (generally of assembled composite shafts 10) shall be interpreted as frame structure 42.

[0119] Hence, in the following, for unification purposes, the term frame structure 42 will be used. The integral, particularly at least widely one-piece manufacture of the frame structure 42 may involve substantial effects. In some embodiments, compared to multi-part frame structures, joining procedures may be avoided. The joining of multi-part frame structures requires, on the one hand, respective joining operations and, on the other hand, a respective pre-processing of the joining surfaces. It is therefore a main advantage to form the frame structures 42 in one piece.

[0120] The frame structure 42 according to FIG. 3 that is arranged as a housing 44 comprises a housing wall 50, side bridges 52 and Intermediate bridges 54. Generally, the frame structure 42 defines at least one bearing channel 56, refer particularly to FIG. 5. The bearing channel 56 comprises a plurality of bearing seats 58 that are formed at the frame structure 42 and that are arranged concentrically with respect to one another. Bearing seats 58 are for instance formed in the side bridges 52 and in the intermediate bridges 54. FIG. 3 illustrates that the housing wall 50 of the housing 44 connects the side bridges 52 and the intermediate bridges 54 with one another. FIG. 4 illustrates that the side bridges 52 and the intermediate bridges 54 are connected to one another by longitudinal bridges 60. Both the housing 44 (FIG. 3) and the bearing frame 46 (FIG. 4) are formed in one piece, wherein also installed elements may be provided, for instance pressed-in sleeves, thread inserts, mating sleeves and such like.

[0121] In FIG. 5 there is further indicated by a double arrow designated by 64 a first direction or feeding direction which may also be referred to as radial feeding direction. Further, by means of a double arrow designated by 66, a second feeding direction is indicated which may also be referred to as axial feeding direction. The axial feeding direction 66 is generally parallel or concentric with respect to the longitudinal extension of the bearing channel 56 defined by the bearing seats 58. Generally, the radial feeding direction 64 is basically perpendicular to the bearing channel 56.

[0122] With particular reference to FIG. 2 and FIG. 5, further a feeding concept for the hollow shaft 16 and the attachment parts 20 to be attached at or on the hollow shaft 16 will be elucidated. In some embodiments, the cams 22 are in their radial extension (or their outline) greater than at least some of the bearing seats 58 of the bearing channel 56. This means in other words that respective cams 22 or a similar attachment part 20 can actually not just axially be inserted into the bearing channel 56 through the bearing seat 58. Hence, at least the cams 22 are fed towards the bearing channel 56 radially in the first feeding direction 64. The same may apply to at least some of the other attachment parts 20.

[0123] It is basically also conceivable that at least some of the attachment parts 20 are fed axially in the second feeding direction 66, for instance those bearings 28 that are mounted or pressed-in at the bearing seat 58 of the side bridges 52. Those bearings 28 that are mounted, for instance, between two cams 22 at the hollow shaft 16 are inserted, by way of example, by means of a combined movement involving first feeding in the first feeding direction 64 and, subsequently, in the second feeding direction 66 into a respective bearing seat 58 of an intermediate bridge 54.

[0124] The frame structures 42 illustrated in FIGS. 3 to 5 are not accessible for the hollow shaft 16 in the first feeding direction (radial feeding direction) 64. This is primarily caused by the fact that at least some of the bearing seats 58 are arranged as circumferential or closed bearing seats. In other words, the hollow shaft 16 may not be readily inserted radially through the intermediate bridges 54 or the side bridges 52 towards its desired end position in the bearing channel 56. Hence, the hollow shaft 16 has to be fed axially in the second feeding direction 66. An assembly of the cam shaft may therefore be formed just in the frame structure 42. The joint cam shaft 12 is accommodated in the finally assembled or joined state in the frame structure 42 in a loss-proof fashion and may not be disassembled or detached non-destructively.

[0125] An exemplary joining procedure for the cam shaft 12 will be illustrated and described in more detail hereinafter with reference to FIGS. 6 to 9.

[0126] FIG. 6 shows a simplified cross-section through an at least pre-assembled cam shaft 12. The cam shaft 12 is inserted into a bearing channel 58 of a frame structure 42 and rotatably mounted by means of bearings 28 at respective bearing seats 58 of side bridges 52 and intermediate bridges 54. The cam shaft 12 comprises a hollow shaft 16 having a hollow profile 18 indicated by dashed lines, wherein a plurality of attachment parts 20, for instance cams 22 is mounted at the hollow shaft 16. The cam shaft 12 further comprises a sprocket or toothed wheel 24 that is disposed at one of the two ends of the hollow shaft 16. The cams 22 and the toothed wheel 24 are mounted at the hollow shaft 16 in a torque-proof fashion.

[0127] FIG. 6 exemplarily illustrates an orientation in which the respective functional module 30 is viewed “from above” or “from the bottom”. FIG. 7 shows a further schematic, greatly simplified longitudinal cross-section through the cam shaft 12 having an orientation that is rotated by 90° with respect to the orientation of FIG. 6. The view plane of FIG. 7 is perpendicular to the view plane of FIG. 6. In FIG. 7, for illustrative purposes, the frame structure 42 is omitted.

[0128] As already described herein before, a feeding or inserting of the hollow shaft 16 is performed in the axial feeding direction 66. However, before the hollow shaft 16 is inserted into the bearing channel 56, the attachment parts 20, for instance the cams 22, are respectively inserted into the bearing channel 56 so that the hollow shaft 16 may extend therethrough. The cams 22 may thus be basically inserted into the bearing channel radially in the first feeding direction 64 “from above”, or “from the bottom”, to be at least pre-joined or pre-assembled therein with the hollow shaft 16. A (final) joining of the hollow shaft 16 with the cams 22, the toothed wheel 24 or other attachment parts 20 is performed by widening, for instance. In some embodiments, the final joining is performed by a local widening of the hollow shaft 16, refer to double arrows in FIG. 7 that are designated by 80.

[0129] The widening may be for instance performed by means of a deformation tool 70 that is adapted to the hollow profile 18 of the hollow shaft 16. The deformation tool 70 comprises a mandrel 72 which may also be referred to as shaft or lance. The mandrel 72 comprises at least one deformation section 74, refer to FIG. 7, for instance. The deformation section 74 is generally (axially) delimited by a sealing arrangement 76. In this context, further reference is made to FIG. 9. By way of example, the at least one channel 82 for a fluid is formed in the deformation tool 70, wherein the fluid is supplied for widening the hollow shaft 16 with high pressure at the deformation section 74. The deformation section 74 is sealed by the sealing arrangement 76 to the exterior when the deformation tool 70 is respectively inserted into the hollow shaft 16. Accordingly, locally a very huge pressure may be applied sectionally and radially to the hollow shaft 16 to widen the same. Accordingly, a plastic deformation of the hollow shaft 16 may be induced.

[0130] In some embodiments, the widening of the hollow shaft 16 is respectively performed at least in support sections 78 that are associated with attachment parts 20, for instance with cams 22 or gear wheels 24. In this context, reference is made again to double arrows designated by 80 in FIG. 7 that indicate widened regions or regions to be widened of the hollow shaft 16. The hollow shaft 16 may further comprise so-called bearing sections 84 at which bearing 28 are mounted that do not necessarily have to be pressed-on with such a huge preload with the hollow shaft 16. Accordingly, in the bearing sections 84, it is not absolutely necessary to perform a respective widening of the hollow shaft 16 by the deformation tool 70. It is nevertheless conceivable that at least inner rings of a bearing 28 are fixed at or on the hollow shaft 16 by widening, for instance. It is also conceivable to form running surfaces for bearing 28 directly at the hollow shaft 16 so that bearing inner shells may be dispensed with.

[0131] It is basically also conceivable to form the deformation tool 70 in such a way that all support sections 78 are widened in one step. Accordingly, the mandrel or shaft 72 of the deformation tool 70 would have to be adapted to the overall extension of the hollow shaft 16 and the support sections 78 defined thereon, and would have to be provided with a plurality of deformation sections 74. It is however also conceivable to sequentially widen the support sections 78 piece by piece.

[0132] In FIG. 7 there is further indicated by 88 a positioning support for a cam 22. The positioning support is arranged to define a joining position of the cam 22 at a sufficiently high accuracy to ensure that the cam 22 is fixedly joined with the support section 78 in its desired position and orientation with respect to the hollow shaft 16 and/or to the remaining cams 22. The positioning support 88 may be associated with one cam 22, however but also with a plurality of cams 22. The positioning support 88 is primarily arranged to predefine a rotation position or angular position of the cam. The positioning support 88 is, in certain embodiments, not intended to form a counterholder or die for the cam 22, when the cam 22 is fixed at the hollow shaft 16 by widening the respective support section 78. As the cam 22 does not have to be necessarily supported by a counterholder (a matrix, a die or such like), the running surface of the cam 22 is accessible for measurement equipment to monitor the widening and/or the joining procedure.

[0133] FIG. 8 shows a detailed view of the hollow shaft 16 being inserted or threaded into the frame structure 42. The feeding is performed axially, refer to the second feeding direction 66. Accordingly, the hollow shaft 16 may be guided at its first end, where for instance a tapering 92 is formed, through a bearing 28 that is mounted at a bearing seat 58 of a side bridge or intermediate bridge 54. FIG. 8 further shows a cam 22 that comprises a maximum dimension 98 that is greater than an inner diameter 96 of the bearing seat 58. Accordingly, the cam 22 may not be axially fed in the second feeding direction 66 through the bearing seat 58. Instead, the cam 22 is radially fed in the first feeding direction 64 towards the bearing channel 56.

[0134] In some embodiments, the joining procedure between the hollow shaft 16 and the attachment parts to be fixed thereon is not just performed by thermal joining exploiting the thermal expansion of the hollow shaft 16 and/or the attachment parts 20. In some embodiments, the widening of the support section 78 for joining the support section 78 with the mounting seat 90 of the attachment part 20 or cam 22 is performed without using a die or a respective counterholder at the outer circumference of the attachment parts 20 or cam 22. As the assembly play (outer diameter 100-inner diameter 102) is just very small, only a small widening of the hollow shaft 16 is required to ensure a sufficiently fixed mounting of the attachment part 20. In some embodiments, this is performed with only small form changes and/or shape changes at the outer circumference of the attachment part 20 or cam 22. Accordingly, an effortful fixation by means of a matrix or a respectively arranged counterholder (also: die) may be dispensed with.

[0135] In some embodiments, for a pre-assembling of the hollow shaft 16, an inner diameter 102 of the mounting seat 90 is at least slightly larger than an outer diameter 100 of the hollow shaft 16, for instance of the support section 78 that is associated with the mounting seat 90. In some embodiments, the resulting assembly play is nevertheless as small as possible. In this way, already a relatively small widening of the hollow shaft 16 may namely ensure a sufficiently tight fit of the cam 22 at the support section 78.

[0136] With reference to FIGS. 10, 11, 12 and 13, an illustrative assembly procedure for joining a cam shaft 12 in a frame structure and/or a housing 44 is elucidated. The housing 44 is, for illustrative purposes, merely indicated as a block. Further, again for illustrative purposes, in FIGS. 11, 12 and 13 the block representation of the housing 44 is omitted.

[0137] FIG. 10 elucidates a state in which attachment parts, for instance cams 22 are already fed to the housing 44 and oriented therein in positioning supports 88, for instance. This is not explicitly shown in FIG. 10. Now, a hollow shaft 16 may be axially (laterally) inserted, and may extend through the mounting seats 90 of the cams 22, refer in this context also to an arrow designated by 104 for illustrating an axial assembly direction, refer also to the illustration in FIG. 8. By way of example, the cam shaft 12 to be joined comprises in total four pairs of cams. FIG. 11 shows that the cams 22 are oriented by means of positioning supports 88 in such a way that their mounting seats 90 are aligned to be joined with the hollow shaft 16. A separate positioning support 88-1, 88-2, 88-3 and 88-4 is associated with each of the pairs of cams.

[0138] Positioning support 88-1 is associated with a first pair of cams, positioning support 88-2 is associated with a second pair of cams, positioning support 88-3 is associated with a third pair of cams and positioning support 88-4 is associated with a fourth pair of cams. It goes without saying that also only a single positioning support 88 may be provided that respectively aligns all pairs of cams.

[0139] In addition to the aligned orientation, the positioning supports 88-1, 88-2, 88-3 and 88-4 effectuate a defined angular orientation of any cams 22 of the pairs of cams. It can be seen in particular with reference to FIGS. 10 and 11 that this may initially involve a similar angular orientation of any cams 22 or pairs of cams. This orientation does not correspond to the desired relative orientation of the cams 22 in the finally joined state. The joining of the hollow shaft 16 with the cams 22 is performed by sectionally plastically widening the hollow shaft hollow shaft 16, refer also to FIG. 9, as already described herein before. To this end, a deformation tool 70 is inserted into the hollow shaft 16.

[0140] At the transition between this states according to FIG. 11 and FIG. 12, already the first pair of cams that was oriented before by the positioning support 88-1 is already pressed-in or fixed with the hollow shaft 16 in a torsionally rigid fashion by sectionally widening the hollow shaft 16. This may be performed in the aligned orientation in the positioning support 88-1 as shown in FIG. 11, for instance, when the hollow shaft 16 is respectively positioned. Before the hollow shaft 16 is then joined with the second pair of cams that is oriented by the positioning support 88-2, now an angular orientation of the hollow shaft 16 with respect to the second pair of cams is performed to effectuate the desired orientation between the first pair of cams and the second pair of cams. This is achieved by means of a defined rotation of the hollow shaft, refer also to a curved arrow designated by 106 in FIG. 12. Subsequently, the second pair of cams may be joined by sectionally widening the hollow shaft 16.

[0141] FIG. 13 indicates that similarly the third pair of cams may be joined that is in FIG. 12 still oriented by means of the positioning support 88-3. Accordingly, again a defined orientation of the hollow shaft 16 to effectuate the desired angular orientation between the third pair of cams and the already joined pairs of cams takes place. Similarly, also the fourth pair of cams may be joined. Overall, a sequential assembly procedure is present that comprises a repeated sequence of orientating and joining.

[0142] It goes without saying that the sequential assembly procedure illustrated with reference to FIGS. 10 to 13 may be also applied to each single attachment part 20, for instance to each single cam 22. Accordingly, each cam 22, also each cam of each pair of cams, may be separately (mediately) oriented by rotating the hollow shaft 16, and may be joined by sectionally widening the hollow shaft 16. This embodiment has the further advantage over the embodiment illustrated with reference to FIGS. 10 to 13 that the positioning support 88 and/or components thereof may be designed even more simple. Further, there may be the effect that respectively only a very small axial section of the hollow shaft 16 has to be widened, refer to the support section 78 in FIG. 6.

[0143] FIG. 14 shows a greatly simplified schematic block diagram of a conceivable sequence of an assembly procedure that utilizes at least some aspects of the present disclosure. It goes without saying that the method may involve optional steps, and that further supplements of the method by further steps or alternative steps are conceivable without departing from fundamental main aspects of the disclosure.

[0144] The method may involve different provision steps S10, S12, S14, and S16. The step S10 involves the provision of a frame structure, for instance of a frame structure that forms a closed bearing channel. The frame structure may also be arranged as a housing or a bearing frame. In some embodiments, the frame structure may involve a housing of frame component that is formed in one piece and that defines a bearing channel having a plurality of bearing seats that are formed to be circumferentially closed.

[0145] The step S12 may involve the provision of at least one bearing, for instance of at least one roller bearing and/or slide bearing. Generally, cam shafts and similar assembled shafts are mounted by means of a plurality of bearings at the frame structure.

[0146] The step S14 may involve the provision of attachment parts that form an assembled composite shaft together with a pre-product (also support shaft) that is arranged as a hollow shaft. The attachment parts may be arranged, for instance, as cams, gear wheels, sprockets, flanges and similar components. In some embodiments, at least some of the components are arranged to be attached to the hollow shaft in a torsionally rigid fashion for rotary driving.

[0147] The step S16 may thus involve the provision of a pre-product which may also be referred to as support shaft. In some embodiments, step S16 comprises a provision of a hollow shaft that is provided with a hollow profile. The hollow shaft may be for instance tubular. The hollow shaft may also comprise stepped sections.

[0148] Subsequent to the provision steps S10, S14, and S16, machining steps S20, S22, S24 may follow. The step S20 may involve machining at least one bearing seat of the bearing channel defined by the frame structure. In this way, an appropriate seat for the bearing(s) provided in the step S12 may be formed at the frame structure.

[0149] The step S22 may involve machining at least one mounting seat of an attachment part. The step S24 may involve machining at least one support section at the hollow shaft and/or the support shaft.

[0150] Ideally, the steps S22 and S24 are adapted to one another so that for instance an inner diameter that is manufactured in the step S22 is adapted to an outer diameter that is formed in the step S24. Ideally, the inner diameter and outer diameter formed in the steps S22, S24 are adapted to one another in such a way that, at room temperature, a simple joining (threading in) of the support shaft through the mounting seat of the attachment part is enabled. In a step S24, the entire support shaft may be machined. It is, however, also conceivable that the support shaft is only sectionally machined in the region of its support sections. In some embodiments, the assembly play that is formed in the steps S22 and S24 is minimized in such a way that already a slight widening of the support shaft in a subsequent step may form a rigid, for instance a torque-proof joint between the support shaft and the attachment parts.

[0151] A first joining step S30 may follow that involves equipping the frame structure with the bearings provided in the step S12.

[0152] A further step S32 may follow that may for instance involve a feeding of the attachment parts provided in the step S14 into the bearing channel of the frame structure. This may for instance involve a defined (rough-) orientation and a (rough-) positioning of the attachment parts. Ideally, the supplied attachment parts are oriented in their mounting seats aligned with the bearing seats of the bearing channel. At least some of the attachment parts are radially fed.

[0153] In accordance with one embodiment, step S32 involves an alignment of at least some of the attachment parts. This may involve, on the one hand, an alignment of some or all attachment parts in their desired relative position with respect to one another that they should also have in the final state. By way of example, cams of cam shafts have to be angularly positioned with respect to one another with high precision to achieve the desired controlled timing of the valve drive. This relates on the one hand to the relative position between inlet and outlet cams of a pair of cams, but also relates to the orientation among the pairs of cams.

[0154] On the other hand, it is conceivable in accordance with an alternative embodiment to indeed define the attachment parts in a defined fashion, but deliberately not in their final relative position with respect to one another. This may involve that the attachment parts, for instance all cams or at least a subset of the cams, are oriented in a common angular position, for instance at a common positioning support.

[0155] As an intermediate step it is conceivable to orient inlet cams and outlet cams of each pair of cams of a plurality of cams already in the step S32 defined with respect to one another, for instance in a common positioning support that defines a desired angular offset. The desired final relative position between the single pairs of cams, however, would be not adjusted in the step S32 with high precision then. Rather, the pairs of cams could be orientated in a common angular position that deviates from the desired final orientation with respect to one another.

[0156] A step S34 may follow that involves supplying, for instance axially supplying the support shaft. Accordingly, the support shaft may be guided through the bearings, for instance through the inner diameter thereof, and through the attachment parts, for instance through the mounting seats thereof, to assume its target-position in the frame structure.

[0157] In a further step S36 that may basically form a part of the steps S32 and S34, an orientation adjustment of the support shaft and of the attachment parts to be attached thereto is performed. This may involve an axial orientation, but also a rotation orientation. In some embodiments, when the attachment parts involve a plurality of cams, a respective relative position of the cams (angular position) is of great significance. Hence, this may be effectuated in the step S36 for instance by means of gages or similar positioning supports, but, depending on the embodiment, also already in the step S32, at least in part.

[0158] A joining step S38 may follow that involves a sectional widening of the support shaft, for instance. This may be for instance effectuated by means of a deformation tool, for instance a mandrel-shaped or shaft-shaped deformation tool that is arranged to apply a pressure to the support shaft from the interior that the support shaft is at least sectionally widened. In this way, a high-strength joint, for instance a torsionally rigid joint between the support shaft and at least some of the attachment parts may be formed.

[0159] A dashed arrow designated by S40 indicates that the steps S36 and S38 alternatively may be repeatedly executed, for instance sequentially. In accordance with this embodiment the position adjusting and the joining by widening the support shaft are thus sequentially performed. The step S36 may involve in a first execution, the desired axial positioning of the support shaft, hence also the overall insertion of the support shaft.

[0160] In the first execution, the step S36 may further involve an adjustment of the angular position between the support shaft and a first attachment part (for instance a first cam). A first execution of the steps S38 may follow, wherein a section of the support shaft is plastically widened and hence a rigid joint between the support shaft and the first attachment part is formed.

[0161] A further execution of the steps S36 and S38 may thus involve a further adjustment of the angular position between the support shaft and a further attachment part. In other words, the first attachment part that is already fixed at the support shaft is rotated together with the support shaft with respect to the next attachment part to effectuate the desired relative angular orientation between the attachment parts (for instance the cams).

[0162] The steps S36 and S38 may be repeated until any attachment parts are fixed to the support shaft in the desired relative (angular) position. At each execution, the support shaft may be respectively rotated. Further, the deformation tool may be axially moved at each execution of the steps S36 and S38 to widen a further section of the support shaft.

[0163] The sequential joining may require once again a position adjustment and a widening. In the alternative, it is also conceivable, for instance with pairs of cams involving inlet cams and outlet cams, to jointly join a subset (e.g. two) of the attachment parts and, respectively, to orientate the support shaft with respect to this subset beforehand. This may require a pre-alignment (relative alignment) of the attachment parts of the subset with respect to one another.

[0164] Ideally, at least the pre-assembly and the final joining of the attachment parts and the support shaft are performed without exploiting the thermal expansion of the used materials.

[0165] In some embodiments, the method is substantially finished at the step S38 and/or subsequent to the sequential executing of the steps S36 and S38. This involves that no post-processing at the support shaft and the attachment parts attached thereto is necessary, as least in some embodiments. In some embodiments, the joining is performed at high precision so that no post-processing of revolving circumferential surfaces of the cams is necessary.

[0166] In accordance with alternative embodiments, the method according to FIG. 14 may be modified. Further, the subject-matter of the disclosure also covers a method for joining an assembled composite shaft that does not necessarily have the step S10 and/or the step S20 as an upstream step. Rather, the feeding, aligning and joining of the hollow shaft and the attachment parts, for instance in accordance with the steps S30 to S40, may also be performed on the outside of a frame structure that involves a bearing channel. Also in the context of this embodiment, several effects may be achieved, in for instance in regard of the reduction and/or prevention of a post-processing and/or finishing processing. In this way, for instance cam shafts and similar composite shafts may be formed wherein bearings and/or similar attachment parts are attached and/or at least partially integrated.