Vehicle driveline assembly and method of manufacturing the assembly

Abstract

A vehicle driveline assembly (10) and a method for manufacturing the assembly of a first torque transmitting member (12) and a second torque transmitting member (14), one of the first and second torque transmitting members being aluminum and the other being steel, the first and second torque transmitting members being joined by a gradually applied electromagnetic pulse weld (16) along a radial direction relative to an axis of rotation (A) of the assembly to provide a lightweight structure.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 62 / 744,328, filed on October 11, 2018, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This invention relates to a vehicle drivetrain assembly for transmitting torque between a vehicle engine and drive wheels, and also to a method for manufacturing the vehicle drivetrain assembly. Background Technology

[0004] The vehicle's drivetrain components are used to transmit torque between the vehicle's power unit and drive wheels as the vehicle rotates about its central axis during travel. Summary of the Invention

[0005] The present invention provides a vehicle drivetrain assembly comprising a first torque transmission member and a second torque transmission member, one of which is aluminum and the other is steel. The first torque transmission member and the second torque transmission member are joined by an electromagnetic pulse weld that is gradually applied in a radial direction relative to the central axis of the assembly, thereby providing a lightweight structure.

[0006] The disclosed vehicle drivetrain assembly according to the invention includes a first torque transmission member made of aluminum and having a flat plate portion with a circular opening through which the central axis of the assembly extends. The vehicle drivetrain assembly also includes a second torque transmission member made of steel and having an annular connection portion that faces axially relative to the central axis and extends around the circular opening of the flat plate portion of the first aluminum member. An electromagnetic pulse weld is formed in the vehicle drivetrain assembly, connecting the plate portion of the first aluminum member around its circular opening to the connection portion of the second steel member.

[0007] As disclosed, the first aluminum component is a clutch hub or housing with a splined portion having axially extending thin walls, and the second steel component is a sun gear, ring gear, torque transmission hub, or shaft.

[0008] As disclosed in another embodiment of the vehicle drivetrain assembly, the electromagnetic pulse weld includes aluminum of a four-digit grade, the first digit of which is lower than the first digit of the four-digit grade of the aluminum of the first aluminum member located away from the weld.

[0009] The disclosed method for manufacturing a vehicle drivetrain assembly according to the invention is performed by the following steps: positioning a flat portion of a first torque-transmitting aluminum member in a spaced-apart relationship adjacent to an annular connection portion of a second torque-transmitting steel member, wherein the flat portion has a circular opening with a central axis, the connection portion being axially oriented relative to the central axis and extending around the opening of the first aluminum member; and applying an electromagnetic pulse weld, which forms and welds the flat portion of the first aluminum member to the connection portion of the second steel member.

[0010] As disclosed, the method uses a first aluminum component and a second steel component, wherein the first aluminum component is a clutch hub or housing with a splined portion having axially extending thin walls, and the second steel component is a sun gear, ring gear, torque transmission hub, or shaft.

[0011] As disclosed in another practice of a method for manufacturing vehicle drivetrain components, a third component, made of aluminum of a lower grade than that of the first aluminum component, is positioned between the first aluminum component and the second steel component prior to performing electromagnetic pulse welding. The thickness of the third aluminum component is less than 3 mm, and as disclosed, is 1.5 mm. Attached Figure Description

[0012] Figure 1 It is a cross-sectional view without most of its background used to illustrate a vehicle powertrain assembly having aluminum and steel components connected to each other by electromagnetic pulse welding.

[0013] Figure 1a This shows a part of the vehicle's drivetrain components. Figure 1 An enlarged view of a portion of the image, showing the aluminum component being formed and then electromagnetically pulsed onto a steel component.

[0014] Figure 1b It is along Figure 1 A partial cross-sectional view of the thin-walled spline portion of the aluminum component is shown by taking a section along line 1b-1b.

[0015] Figure 2 Is it like this? Figure 1 A cross-sectional view of a vehicle drivetrain component taken before electromagnetic pulse welding, as shown in the image.

[0016] Figure 2a It is similar to Figure 1a But before the formation and electromagnetic pulse welding Figure 2 A magnified view of a portion of it.

[0017] Figure 3 Therefore, with Figure 1A view of another embodiment of a vehicle drivetrain assembly, cut in the same cross-sectional manner but also having another aluminum component, which is of a lower grade than the first aluminum component and is located at the electromagnetic pulse weld to enhance weld strength.

[0018] Figure 3a It is similar to Figure 1a of Figure 3 An enlarged view of a portion of the image shows additional aluminum components at the site of the formed electromagnetic pulse weld.

[0019] Figure 4 yes Figure 3 The view shows an alternative embodiment of the vehicle drivetrain assembly, and is similar to... Figure 2 exist Figure 3 and Figure 3a The formation shown is before electromagnetic pulse welding.

[0020] Figure 4a yes Figure 4 An enlarged view of a portion of the image, showing the vehicle drivetrain components prior to formation and electromagnetic pulse welding.

[0021] Figure 5 It shows that Figure 1 and Figure 2 The implementation method forms a weld on its aluminum component by progressively performing electromagnetic pulse welding along a radial direction relative to the central axis of the vehicle drivetrain assembly.

[0022] Figure 6 It is similar to Figure 5 The view that shows Figure 3 and Figure 4 The two aluminum components in the embodiment are formed by forming a weld seam by gradually forming the two aluminum components by electromagnetic pulse welding in a radial direction relative to the central axis of the vehicle drivetrain assembly.

[0023] Figure 7 It is a greatly magnified view that shows the atomic bonds between the aluminum and steel components.

[0024] Figure 8 This shows the processing. Figure 1 , Figure 1a , Figure 2 , Figure 2a and Figure 5 A flowchart illustrating one embodiment of a vehicle drivetrain assembly is shown.

[0025] Figure 9 This shows the processing. Figure 3 , Figure 3a , Figure 4 , Figure 4a and Figure 6 Another flowchart showing the method of another vehicle drivetrain component. Detailed Implementation

[0026] Reference Figure 1 The vehicle drivetrain assembly, generally designated 10, is constructed according to the invention using the method described herein, and includes a first torque transmission member 12 made of aluminum, a second torque transmission member 14 made of steel, and an electromagnetic pulse weld 16 connecting these members to each other, which is described more fully below. The construction of the vehicle drivetrain assembly 10 and the method of manufacturing it will both be described in a unified manner to facilitate understanding of the different aspects of the invention.

[0027] Continue to refer to Figure 1 The first torque transmission member 12 includes a circular flat plate portion 18 having a central circular opening 20 through which the rotational axis A of the assembly extends. The second torque transmission member 14 includes an annular connection portion 22, which is relative to... Figure 2 b is the central axis A shown in the best orientation, facing axially and extending around the central circular opening 20 of the flat plate portion 18 of the first torque transmission member 12. Figure 1b The electromagnetic pulse weld 16 shown forms and connects the flat plate portion 18 of the first torque transmission member 12 around its central circular opening 20 to the annular connection portion 22 of the second torque transmission member 14. Therefore, the second torque transmission member 14 has the required durability, while the first torque transmission member 12 advantageously provides a lighter construction for the vehicle drivetrain assembly than if made of steel.

[0028] like Figure 1 and Figure 2 As shown, the first torque transmission member 12 is a clutch hub or housing that defines a flat plate portion 18 and also has an axially extending thin-walled splined portion 24, the thin-walled splined portion 24 including... Figure 1b The thin-walled spline 26 is shown.

[0029] Similarly, Figure 1 and Figure 2 As shown, the second torque transmission member 14 is shown as a sun gear with helical teeth 28, and can also be configured as a ring gear, torque transmission hub or shaft.

[0030] like Figure 5 As shown, electromagnetic pulse welding gradually forms an electromagnetic pulse weld 16 from the flat plate portion 18 of the first torque transmission member 12 to the second torque transmission member 14 in a radial direction relative to the central axis of the assembly, as indicated by schematic arrow 30. Electromagnetic pulse welding provides atomic-level... Figure 7A greatly magnified (1000x) view shows the electromagnetic pulse weld 16, which is used to fix aluminum and steel together.

[0031] like Figure 8 As shown, flowchart 32 illustrates the positioning of the aluminum and steel components adjacent to each other in step 34 (also... Figure 2 (as shown in the figure), and step 36 shows the application of an electromagnetic pulse weld to form atomic bonds between aluminum and steel.

[0032] Reference Figure 3 , Figure 3a , Figure 4 and Figure 4a Another embodiment of the vehicle drivetrain assembly is generally indicated by 10', and except as will be discussed, this other embodiment has the same construction as the aforementioned embodiment. Thus, similar reference numerals are applied to their similar parts, and many of the previous descriptions are applicable and need not be repeated, and therefore will not be repeated. However, in embodiment 10', another aluminum member 38 (such as...) is initially positioned between the annular connection portion 22 of the second torque transmission member 14 and the flat plate portion 18 of the first torque transmission member 12. Figure 4a As shown, this is in preparation for electromagnetic pulse welding. The aluminum component 38 has a lower aluminum grade than the first torque transmission component 12, thus enhancing the atomic bonding with the second torque transmission component 14. More specifically, the first digit of the four-digit member of the grade of the aluminum component 38 is lower than the first digit of the four-digit member of the grade of the first torque transmission component 12, making it easier to form because the aluminum component 38 has less strength due to less alloying. Furthermore, the aluminum component 38 extends around the central circular opening 20 of the flat plate portion 18 of the first torque transmission component 12 and is positioned adjacent to the annular connection portion 22 of the steel component, where electromagnetic pulse welding provides atomic bonding. In addition, the thickness of the aluminum component 38 is less than 3 mm, preferably 1.5 mm, which means 1.5 mm in this context with a tolerance of ±10%, so the relatively thin aluminum has a less mass than the thicker aluminum component. Therefore, the aluminum component 38 is accelerated more quickly and has a greater impact to provide better atomic bonding with the steel, as also provided by the lower grade of the aluminum component with less alloying. The thicker first torque transmission member 12 is also bonded to the lower grade of aluminum atoms in the thinner aluminum member 38.

[0033] like Figure 6 As shown, electromagnetic pulse welding causes the flat plate portion 18 of the first torque transmission member 12 and the aluminum member 38 to gradually form an electromagnetic pulse weld 16 with the second torque transmission member 14 in the radial direction relative to the central axis of the assembly, as indicated by schematic arrow 30.

[0034] like Figure 9 As shown, flowchart 32' in step 34' illustrates the positioning of the first torque transmission member 12 and the aluminum member 38 and the second torque transmission member 14 adjacent to each other (also in... Figure 3 (as shown in the diagram), and step 36 shows the next step of applying an electromagnetic pulse weld to form atomic bonds between the aluminum and the steel.

[0035] Although exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the language used in this specification is descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the invention. Furthermore, features of various embodiments can be combined to form other embodiments of the invention.

Claims

1. A vehicle drivetrain assembly, comprising: A first torque transmission component, which is made of aluminum and includes a flat plate portion having a circular opening, the central axis of the component extending through the circular opening; The second torque transmission member is made of steel and includes an annular connection portion that extends axially relative to the central axis and around the circular opening of the flat plate portion of the first torque transmission member. An electromagnetic pulse weld is formed, which connects the flat plate portion of the first torque transmission member surrounding its circular opening to the connection portion of the second torque transmission member. The first torque transmission component is a clutch hub or housing having an axially extending thin-walled spline portion. The electromagnetic pulse weld is applied gradually along a radial direction relative to the central axis of the assembly; and A third component, located between the first torque transmission component and the second torque transmission component, is made of aluminum of a four-digit grade, the first digit of which is lower than the first digit of the four-digit grade of the aluminum of the first torque transmission component, and the third component has lower strength due to less alloying, wherein the third component is thinner than the first torque transmission component and has a thickness of less than 3 mm, and wherein the third component is atomically bonded to the first torque transmission component and the second torque transmission component.

2. The vehicle drivetrain assembly according to claim 1, wherein, The second torque transmission component is a sun gear, a ring gear, a torque transmission hub, or a shaft.

3. The vehicle drivetrain assembly according to claim 1, wherein, The electromagnetic pulse weld seam includes aluminum in a four-digit grade, the first digit of which is lower than the first digit of the four-digit grade of aluminum in the first torque transmission member located away from the weld seam.

4. A method for manufacturing a vehicle powertrain assembly, the method comprising: The flat plate portion of the torque transmission aluminum component is positioned in a spaced-apart relationship adjacent to the annular connection portion of the torque transmission steel component, wherein the flat plate portion has a circular opening with a central axis, and the connection portion extends axially relative to the central axis and around the opening of the torque transmission aluminum component. An electromagnetic pulse weld is applied, which forms and welds the flat portion of the torque-transmitting aluminum component to the connection point of the torque-transmitting steel component. The torque transmission aluminum component is a clutch hub or housing with an axially extending thin-walled spline portion; The electromagnetic pulse weld is applied gradually along a radial direction relative to the central axis of the assembly; and An intermediate aluminum component is provided between the torque transmission aluminum component and the torque transmission steel component. This intermediate aluminum component is made of aluminum with a four-digit grade, where the first digit of the grade is lower than that of the torque transmission aluminum component. Furthermore, the intermediate aluminum component has lower strength due to less alloying, and it is thinner than the torque transmission aluminum component, having a thickness of less than 3 mm. The application step involves atomically bonding the intermediate aluminum component with the torque transmission aluminum component and the torque transmission steel component.

5. The method for manufacturing a vehicle powertrain assembly according to claim 4, wherein, The torque transmission steel component is a sun gear, a ring gear, a torque transmission hub, or a shaft.

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