Power transmission component and assembly

Abstract

A planetary gear set component includes a first carrier plate, a second carrier plate, and a plurality of legs extending between the first carrier plate and the second carrier plate. The second bearing plate has an inner surface and an outer surface. The legs extend between the first and second carrier plates and contact an inner surface of the second carrier plate. The second carrier plate includes a plurality of notches in an outer surface of the second carrier plate and a flange extending axially from the outer surface of the second carrier plate. The flange surrounds the groove. The second bearing plate is made of powder metal.

Description

TECHNICAL FIELD

[0001] The present invention relates generally to a power transmission component; and more particularly to a component for use with a gear system or gear set. BACKGROUND

[0002] Gear sets or systems including planetary gear systems are used in driveline assemblies. Planetary or epicyclic gear systems include a sun gear, planet gears, and a ring gear. The planet gears mesh with the sun gear and rotate around the sun gear. The ring gear meshes with the planet gears. Rotational motion is transmitted from the sun gear to the planet gears and to the ring gear or otherwise. The planet gears are typically mounted on a planet carrier. The sun gear and the planet carrier rotate about the same rotational axis but can rotate independently of one another. Typically, the rotational axes of all the gears in a planetary gear system are parallel to one another.

[0003] Possible inputs and outputs from a planetary gear system include the sun gear, the ring gear, and the planet carrier. Typically, a planetary gear assembly has a single input and a single output, with a portion of the planetary gear system remaining stationary. The overall gear ratio of a planetary gear assembly varies based on which component remains stationary, which component is the input, and which component is the output.

[0004] A power transmission system can include a one-way clutch component. The one-way clutch component can be used with a gear assembly or gear set. SUMMARY

[0005] A planetary gear set component has a first carrier plate, a second carrier plate, and a plurality of legs extending between the first carrier plate and the second carrier plate. The second carrier plate has an inner surface and an outer surface. The legs extend between the first carrier plate and the second carrier plate and contact the inner surface of the second carrier plate. The second carrier plate includes a flange extending axially from the outer surface of the second carrier plate and a plurality of notches in the second carrier plate. The second carrier plate is made of a powder metal.

[0006] Other applications of the present invention will become apparent from the following detailed description when viewed in connection with the accompanying drawings, which are described as follows: BRIEF DESCRIPTION OF DRAWINGS

[0007] The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

[0008] Figure 1 is a schematic cross-sectional view of a power transmission assembly or vehicle driveline assembly including a planetary gear set according to an example of an embodiment of the present disclosure.

[0009] Figure 2is an example of a planetary carrier for use with a planetary gear set. Figure 1 is another perspective view of an example of a planetary carrier of

[0010] Figure 3 is an example of a planetary carrier of Figure 2 is another perspective view of an example of a planetary carrier of

[0011] Figure 4 is an example of a portion of a planetary carrier of Figure 2 is a perspective view of an example of a portion of a planetary carrier of

[0012] Figure 5 is a perspective view of an example of a portion of a planetary carrier of Figure 2 is a perspective view of an example of a portion of a planetary carrier of

[0013] Figure 6 is another perspective view of an example of a planetary carrier for use with a planetary gear set.

[0014] Figure 7 is another perspective view of an example of a planetary carrier of Figure 6

[0015] is a perspective view of an example of a portion of a planetary carrier of Figure 8 Figure 6 is a perspective view of an example of a portion of a planetary carrier of

[0016] Figure 9 is a perspective view of an example of a portion of a planetary carrier of Figure 6

[0017] is a perspective view of an example of a portion of a planetary carrier of Figure 10 Figure 6 is another perspective view of an example of a planetary carrier for use with a planetary gear set.

[0018] Figure 11 is another perspective view of an example of a planetary carrier of

[0019] Figure 12 Figure 11 is another perspective view of an example of a planetary carrier of

[0020] Figure 13 is a perspective view of an example of a portion of a planetary carrier of Figure 11

[0021] is a perspective view of an example of a portion of a planetary carrier of Figure 14 Figure 11 is a perspective view of an example of a portion of a planetary carrier of

[0022] Figure 15 Figure 11 is a perspective view of an example of a portion of a planetary carrier of DETAILED DESCRIPTION

[0023] ​​​​​The following description of preferred embodiments is merely exemplary in nature and is in no way intended to limit the application, its application, or uses.

[0024] A number of examples of the application are disclosed herein; however, it is understood that these disclosed examples are merely exemplary of the application, which can be embodied in various and alternative forms. The Figures are not necessarily to scale and some features can be exaggerated or minimized for the purpose of clarity. The specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to employ the present application in virtually any appropriately detailed environment.

[0025] Figure 1 An example of a power transmission assembly or vehicle driveline assembly, generally designated 10, is illustrated. The power transmission system or vehicle driveline assembly 10 includes an input shaft 14 and an output shaft 16. The power transmission system or vehicle driveline assembly 10 can include a planetary gear system or gearset, generally designated 12. The term "gearset" broadly refers to a gear mechanism for transmitting motion, and in one example, includes a set of gears that form a set. Figure 1 The planetary gear system or gearset 12 is shown as a simple planetary gearset that utilizes a carrier 20 that supports a single set of planetary gears. The planetary gear system or gearset 12 can also be a compound planetary gearset that utilizes a carrier that supports another set of planetary gears (e.g., two planetary gears that are consistently attached to the same shaft).

[0026] The planetary gear system or gearset 12 transmits power from the input shaft 14 to the output shaft 16 or from the output shaft 16 to the input shaft 14. The planetary gear system or gearset provides mechanical engagement between mating components and acts as a torque transmission mechanism. It can change the speed and torque from the input to the output. The planetary gear system or gearset 12, the output shaft 16, and the input shaft 14 all rotate about a common longitudinal or rotational axis 15.

[0027] The planetary gear system or gearset 12 includes a sun gear 18, a carrier 20, a plurality of planetary gears 22, and a ring gear 24. In the present example, the input shaft 14 is connected to the sun gear 18 and provides input, for example, from a drive motor. The output shaft 16 is connected to the carrier 20 and provides output, for example, to a vehicle driveline of a drive wheel.

[0028] The powertrain or vehicle driveline assembly 10 includes at least one coupling or clutch assembly (generally designated 26) operable to connect and disconnect the output shaft 16 with the planet carrier 20 and, correspondingly, with the planetary gear system or gearset 12. One type of coupling or clutch assembly 26 includes a "one-way" or "overrunning" clutch that creates a driving connection (locked state) between two rotating components when the relative rotation of the two rotating components is in one direction, overruns (freewheel state) between the two rotating components when the relative rotation of the two rotating components is in the opposite direction, and overruns (freewheel state) between the two rotating components when the relative rotation of the two components is in the same direction and when the driven member is rotating faster than the driving member. The overrunning clutch operates when the driving or input portion is rotating slower than the driven member. The direction of driving and overrunning in the opposite direction depends on the direction of rotation of the driving member.

[0029] The one-way clutch can be a controllable or selectable one-way clutch. The controllable or selectable one-way clutch can have its mode of operation selected or controlled whereby the selectable one-way clutch can hold torque or freewheel in one or both directions depending on the desired mode of operation (e.g., engaged or disengaged). In contrast to a basic one-way clutch in which the direction of torque applied to the input member determines the mode of operation, the selectable one-way clutch can transmit torque in one direction but not the other, e.g., from the input to the output shaft but not from the output to the input when the output shaft is rotating in the opposite direction.

[0030] Another example of a selectable one-way clutch includes a dynamically controllable clutch (DCC) in which both races of the clutch are able to rotate, the dynamically controllable clutch operating to selectively couple the output shaft 16 to the planet carrier 20.

[0031] For the purposes of this application, the term "coupling" shall be interpreted to include a clutch or brake, wherein one of the plates is drivingly connected to a torque delivering element of a transmission, engine or motor, and the other plate is connected to another torque delivering element or to ground in the case of a brake. The terms "coupling", "clutch" and "brake" can be used interchangeably. Furthermore, for the purposes of this application, the input shaft 14 and the output shaft 16 are interchangeable. In one example, if the planetary gear system or gear set 12 is used in an electric vehicle operating in regenerative mode, then manual rotation of the wheels turns the electric motor, essentially changing the electric motor to a generator. When operating in regenerative mode, the output shaft 16 can be the input and the input shaft 14 can be the output. In essence, the drive wheels operate as the driving member, transferring torque to the driven member, e.g., the electric motor.

[0032] Figure 1 A coupling or clutch assembly 26 is shown connecting the planet carrier 20 to the output shaft 16. The coupling or clutch assembly 26 includes a first coupling member 28. The first coupling member 28 is referred to as a pocket plate because it includes a receiving area, e.g., a cavity or pocket 32 in a surface or side 30 of the first coupling member 28. The first coupling member can include a plurality of circumferentially spaced pockets 32. These pockets 32 are sized and shaped to receive and nominally hold a torque transmission or locking element 34, e.g., a strut.

[0033] The coupling or clutch assembly 26 includes a second coupling member 36, which is sometimes referred to as a notch plate because it includes a plurality of circumferentially spaced depressions or notches 178 in the second coupling member 36.

[0034] In one example, the coupling or clutch assembly 26 includes an actuation system in the form of a linear motor or linear actuator. The linear motor or actuator includes a stator and a translator. The stator is fixed in place in the housing. The stator can include an induction coil housed between steel plates. The linear actuator actively controls the mode of operation by creating an electromagnetic force with the stator that interacts with the translator, causing the translator to slide and move axially back and forth in the direction of the rotational axis 15 of the input shaft 14 or the output shaft 16.

[0035] The axial movement of the translator acts on an actuation member, e.g., a spring. Other actuators or actuation members besides springs can provide the actuation force.

[0036] An actuator or spring acts on the locking elements 34 to position them in an engaged position in which the locking elements 34 engage or contact the recesses 178 and correspondingly couple the first member 28 and the second coupling member 36 and the input shaft 14 to the output shaft 16. The actuator or spring can act on the locking elements 34 to position them in a disengaged position in the pockets 32 in which the locking members are disengaged, not in contact, from the recesses 178 in the second coupling member 36, correspondingly decoupling the first member 28 and the second coupling member 36 and the input shaft 14 from the output shaft 16.

[0037] The power transmission or vehicle driveline assembly 10 can be an electronically controlled overrunning system disconnect device with multiple modes of operation. Such modes of operation can include forward, reverse, regenerative, disconnect, and overrunning modes of operation.

[0038] Figure 1 is an example of the power transmission or vehicle driveline assembly 10 with portions including an actuation system or linear actuator removed for clarity. The first coupling member 28 is connected, e.g., splined, to the output shaft 16 and the second coupling member 36 is a component of the carrier 20, wherein the output shaft 16 is connected to the carrier 20 through the sun gear 18 and the planetary gears 22. The first coupling member 28 is connected to the output shaft 16 and the second coupling member 36 is connected to the carrier 20. The deployment of the locking elements 34 couples the carrier 20 and the input shaft 14 to the output shaft 16.

[0039] Figures 2-5 is an example of the power transmission or vehicle driveline assembly 10 with portions including an actuation system or linear actuator removed for clarity. The first coupling member 28 is connected, e.g., splined, to the output shaft 16 and the second coupling member 36 is a component of the carrier 20, wherein the output shaft 16 is connected to the carrier 20 through the sun gear 18 and the planetary gears 22. The first coupling member 28 is connected to the output shaft 16 and the second coupling member 36 is connected to the carrier 20. The deployment of the locking elements 34 couples the carrier 20 and the input shaft 14 to the output shaft 16.

[0040] As shown, the carrier 20 includes two interconnected components or pieces, a first bottom plate portion 112 and a second bottom plate portion 114.

[0041] The first bottom plate portion 112 includes a carrier plate 118 having opposite axially facing outboard and inboard surfaces 120, 122. The outer peripheral surface 124 of the carrier plate 118 includes a plurality of recesses 126. The carrier plate 118 includes a central hole or bore 128 and a plurality of bores 130 radially spaced apart from and circumferentially located about the central hole or bore 128. A plurality of legs 132 axially extend from the inboard surface 122 of the carrier plate 118. The legs 132 can be integrally formed with the carrier plate 118. The legs 132 have a generally trapezoidal shape, with the outer surface 134 of the legs 132 being concave. Shaping the legs 132 in this manner reduces the overall weight of the first bottom plate portion 112. Providing the recesses 126 on the outer peripheral side or surface 124 of the carrier plate 118 between the bores 130 and the legs 132 also reduces the overall weight of the first bottom plate portion 112.

[0042] The second bottom plate portion 114 includes a carrier plate 156 having opposite axially facing outboard and inboard surfaces 158, 160. The carrier plate 156 includes a central hole or bore 166 and bores 168 located in the carrier plate 156. The outer peripheral surface 162 of the carrier plate 118 includes a plurality of recesses 125. The recesses 125 are complementary to the concave outer surfaces 134 of the legs 132.

[0043] The second bottom plate portion 114 includes a cylindrical member or flange portion 170 extending axially in the direction of the rotational axis 15. The flange portion 170 extends circumferentially about and axially from the outboard surface 158 and forms a cavity or pocket 172 with the outboard surface 158. The flange portion 170 includes an inner peripheral surface 174 having a groove 176.

[0044] The outboard surface 158 has a plurality of inwardly extending recesses or notches 178 located on or in the outboard surface 158 of the carrier plate 156 of the second bottom plate portion 114 of the planet carrier 20. These recesses or notches 178 have opposite engagement shoulders or surfaces 180, 182. The cavity or pocket 172 accommodates the first coupling member 28, with the snap ring or retaining ring 48 in the groove 176 retaining the first coupling member 28 in the cavity or pocket 172. As Figure 2 shown, the recesses or notches 178 have a trapezoidal shape when viewed axially from the side, with the opposite engagement shoulders or surfaces 180, 182 located at the non-parallel sides of the trapezoidal shape.

[0045] The first bottom plate portion 112 and the second bottom plate portion 114 are assembled and joined to form a single open structure component - the planet carrier 20. As Figures 2-3As shown, the first and second bottom plate portions 112, 114 are interconnected and spaced apart by the legs 132. The planetary gear shafts 184 are connected to the planet carrier 20. In one example, the planetary gear shafts 184 are press fit into the orifices 130, 168 in the carrier plates 118, 156 of the planet carrier 20. In addition to securing the planetary gear shafts 184, the interference fit bonds the planetary gear shafts 184 to the planet carrier 20, allowing them to participate in the strength and stiffness of the planet carrier 20.

[0046] In one example, the first and second bottom plate portions 112, 114 of the planet carrier 20 are separate powder metal parts. Powder metal (PM) parts are made from very fine metal powder that is compressed and sintered to achieve their final shape. Powder metal is a metal shaping operation that uses metal powder pressed into a mold and fused. Powder metal has advantages in material utilization, shape complexity, and near net shape dimensional control, among others. In addition, using powder metal enables weight reduction by taking advantage of the part configuration possibilities associated with powder metal technology. For example, powder metal technology enables complex conditions and geometries to be formed that are difficult to achieve with other metal forming processes. In addition to achieving dimensional tolerances, powder metal parts or components also take advantage of shape possibilities. For example, the legs 132 of the first bottom plate portion 112 can be hollow tubular members with an arcuate profile.

[0047] The powder metal components or parts, the first and second bottom plate portions 112, 114 are assembled and formed into a single member or structure by brazing, which is the joining of metal surfaces with non-ferrous alloys having a lower melting point than the metal being joined using a molten metal or metal alloy. The brazing material is stronger than the base, powder metal material that forms the first and second bottom plate portions 112, 114. Figure 3 Brazing lines 190 are shown at the intersection of the first and second bottom plate portions 112, 114, where the brazing process forms a radius or fillet in place of the sharp corner formed at the intersection of the leg and the bottom plate. Typically, the radius or fillet is about 0.3 mm in size and preferably about 0.5 mm.

[0048] In the example described above, both the first and second bottom plate portions 112, 114 are formed from powder metal. In another example, the planet carrier 20 is formed from powder metal as a single, monolithic one-piece member. In another example, the first bottom plate portion 112 is formed from non-powder metal (e.g., steel) and the second bottom plate portion 114 is made from powder metal. These components are then bonded together.

[0049] The use of powder metal and powder metal processes enables the formation of the recess or pocket 178 integrally with at least one component of the carrier 20, in this example, the second base plate portion 114. The use of powder metal and powder metal manufacturing processes enables the manufacture within dimensional tolerances of the pocket 178, including draft angles and joint angles of the joint surfaces 180, 182.

[0050] The power transmission or vehicle driveline assembly 10 operates to connect or disconnect an input or output shaft with a carrier of a planetary gear set. The assembly provides at least one example of a power transmission or vehicle driveline assembly 10 that couples an output shaft 16 with a carrier 20 of a planetary gear system or gear set 12 having an additional overrunning capability.

[0051] Figures 6-10 Another example of a carrier 100 suitable for use with the power transmission or vehicle driveline assembly 10 is illustrated, where like numbers correspond to like elements in other examples herein. The gear set 12 of the power transmission or vehicle driveline assembly 10 is a compound planetary gear set having an additional set of planetary gears, where the carrier 100 supports the planetary gears of the compound planetary gear set.

[0052] As shown, the carrier 100 includes three interconnected components or pieces - a first base plate portion 112, a second base plate portion 114, and a third base plate portion 116, where the third base plate portion 116 is between the first base plate portion 112 and the second base plate portion 114.

[0053] The first base plate portion 112 includes a carrier plate 118 having opposite axially facing outboard and inboard surfaces 120, 122. The outer peripheral surface 124 of the carrier plate 118 includes a plurality of recesses 126. The carrier plate 118 includes a central bore or aperture 128 and a plurality of apertures 130 radially spaced apart from and circumferentially positioned about the central bore or aperture 128. A plurality of legs 132 axially extend from the inboard surface 122 of the carrier plate 118. The legs 132 can be integrally formed with the carrier plate 118. The legs 132 have a generally trapezoidal shape, where the outer surface 134 of the legs 132 is concave. Shaping the legs 132 in this manner reduces the overall weight of the first base plate portion 112. Providing the recesses 126 on the outer peripheral side or surface 124 of the carrier plate 118 between the apertures 130 and the legs 132 also reduces the overall weight of the first base plate portion 112.

[0054] The third base plate portion 116 includes a plate portion 136 having opposite axially facing side surfaces 138, 140 and a central hole or aperture 142. An outer peripheral side or surface 144 of the plate portion 136 includes a plurality of recesses 146. A plurality of legs 148 extend axially from the side surface 140 of the plate portion 136. The legs 148 have a generally trapezoidal shape, with a portion of an outer surface 150 of the legs 148 being concave. Shaping the legs 148 in this manner reduces the overall weight of the third base plate portion 116. The side surface 138 opposite the legs 148 includes a plurality of trapezoidal notches 152. The notches 152 are shaped to receive end portions 154 of the legs 132 of the first base plate portion 112, with the first base plate portion 112 contacting the third base plate portion 116. For example, the end portions 154 of the legs 132 are nested in the notches 152.

[0055] The second base plate portion 114 includes a carrier plate 156 having opposite axially facing outer and inner side surfaces 158, 160 and an outer peripheral surface 162. The carrier plate 156 includes a central hole or aperture 166 and apertures 168 in respective ears or tabs 164.

[0056] The inner side surface 160 of the carrier plate 156 includes a plurality of notches 186. The notches 186 have a generally trapezoidal shape to receive end portions 188 of the legs 148 of the third base plate portion 116, with the end portions 188 nested in the notches 186.

[0057] The second base plate portion 114 includes an axially extending cylindrical member or flange portion 170 extending laterally from the outer side surface 158. The flange portion 170 extends circumferentially around and axially from the outer side surface 158 and forms a cavity or pocket 172 with the outer side surface 158. The flange portion 170 includes an inner peripheral surface 174 having a groove 176.

[0058] The outer side surface 158 has a plurality of inwardly extending recesses or notches 178 on or in the outer side surface 158 of the carrier plate 156 of the second base plate portion 114 of the planetary carrier 100. The recesses or notches 178 have opposite engagement shoulders or surfaces 180, 182. The cavity or pocket 172 accommodates the first coupling member 28, with the snap ring or retaining ring 48 in the groove 176 retaining the first coupling member 28 in the cavity or pocket 172. As shown, the recesses or notches 178 have a trapezoidal shape when viewed axially from the side, with the opposite engagement shoulders or surfaces 180, 182 being on non-parallel sides of the trapezoidal shape. Figure 6

[0059] ​The first base plate portion 112, the second base plate portion 114, and the third base plate portion 116 are assembled and bonded to form a single open structure component - the planet carrier 100. As shown Figure 7 The third base plate portion 116 is between the first base plate portion 112 and the second base plate portion 114, with the carrier plates 118, 156 spaced apart by the legs 132, 148, respectively.

[0060] The planet gear shafts 184 are connected to the planet carrier 100. In one example, the planet gear shafts 184 are press fit into the orifices 130, 168 in the carrier plates 118, 156 of the planet carrier 100. In addition to securing the planet gear shafts 184, the interference fit bonds the planet gear shafts 184 to the planet carrier 100, allowing them to participate in the strength and stiffness of the planet carrier 100.

[0061] Similar to the previous example, the first base plate portion 112, the second base plate portion 114, and the third base plate portion 116 of the planet carrier 100 can be made of a powder metal. In one example, the legs 132 of the first base plate portion 112 and the legs 148 of the second base plate portion 114 are hollow tubular members with an arcuate profile.

[0062] In one example, the first base plate portion 112, the second base plate portion 114, and the third base plate portion 116 are made of a powder metal and assembled and formed into a single component or structure by brazing - joining a metal surface to a non-ferrous alloy with a lower melting point than the metal being joined using a molten metal or metal alloy. The brazing material is stronger than the base, powder metal material that forms the base plate portions 112, 114, 116. Figure 7 Brazing lines 190 are shown at the intersections of the first base plate portion 112, the second base plate portion 114, and the third base plate portion 116, where the brazing process forms a radius or fillet in place of the sharp corners formed at the intersections of the legs and the base plate.

[0063] In another example, the first base plate portion 112 and the third base plate portion 116 are formed of a non-powder metal, such as steel. The second base plate portion 114 is made of a powder metal. These components are then bonded together.

[0064] Figures 11-15 Another example of a planet carrier 110 is shown, where like numbers correspond to like elements in other examples herein. The gear set 12 of the power transmission or vehicle driveline assembly 10 is a compound planetary gear set with an additional set of planetary gears, with the planet carrier 110 supporting the planetary gears of the compound planetary gear set.

[0065] As illustrated, the carrier plate 118 of the first bottom plate portion 112, the plate portion 136 of the third bottom plate portion 116, and the carrier plate 156 of the second bottom plate portion 114 each have increased mass or more material. As illustrated, the carrier plate 118 of the first bottom plate portion 112 and the carrier plate 156 of the second bottom plate portion 114 have a more rounded shape; the outer peripheral surfaces 124, 162 do not include the recesses of the previous example. Further, the legs 132 of the first bottom plate portion 112 and the legs 148 of the third bottom plate portion 116 also have increased mass; specifically, the outer surfaces 135, 165 of the legs 132, 148 are not concave. They extend axially in unison with the respective outer peripheral surfaces 124, 145 of the carrier plate 118 and the plate portion 136. Further, the legs 132, 148 can be solid members.

[0066] The planetary carrier 110 includes an integral recess or pocket 178 in the multi-piece powder metal assembly. The pocket 178 is located on the outer side surface 158 of the planetary carrier 110.

[0067] The planetary carriers 100, 110 are suitable for use with a compound planetary gear system or gearset and include three components or bottom plate portions 112, 114, 116.

[0068] The planetary carriers 20, 100, 110 described herein incorporate a pocket 178 that mates with a separate clutch or coupling member (e.g., locking element 34) to create a clutch or coupling assembly. It is also possible to incorporate a recess instead of a pocket into the planetary carrier.

[0069] As shown, the planetary carriers 20, 100, 110 include an axial end face or outer side surface 158 having a pocket 178 that forms part of a planar clutch or coupling assembly with the locking elements extending axially. In a further example, the pocket 178 is formed in an inner peripheral surface 174 (radial surface) of an axially extending flange portion 170, creating a radial clutch or coupling assembly with the locking elements extending radially. Instead of a planar clutch feature, the coupling assembly uses a radial clutch feature.

[0070] The foregoing examples of planetary carriers illustrate a multi-piece powder metal assembly that is integrated into a one-piece carrier that has a plurality of pockets in the axial end face or side surface in a form that is known to be manufacturable. The pieces of the planetary carrier can be sinter-brazed.

[0071] Although examples or exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the present invention. The words used in this manual are descriptive words rather than restrictive words, and it should be understood that various changes can be made without departing from the spirit and scope of the present invention. In addition, the features of different embodiments can be combined to form other embodiments of the present invention.

[0072] The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

1. A planet carrier for use with a planetary gear set, comprising: a first carrier plate; a second carrier plate; a plurality of legs extending between the first carrier plate and the second carrier plate; the second carrier plate having an inner surface and an outer surface, the legs extending between the first carrier plate and the second carrier plate contacting the inner surface of the second carrier plate; the second carrier plate including a flange extending axially from the outer surface of the second carrier plate; a plurality of notches in the second carrier plate; and the second carrier plate being made of a powder metal.

2. The planet carrier of claim 1, comprising: the notches being in the outer surface of the second carrier plate; and the flange forming a cylindrical member and encircling the notches, the cylindrical member extending transverse to the outer surface of the second carrier plate.

3. The planet carrier of claim 1, comprising: each of the plurality of notches having opposing engagement surfaces.

4. The planet carrier of claim 3, comprising: each of the plurality of notches having non-parallel sides, wherein the opposing engagement surfaces are at the non-parallel sides of the notches.

5. The planet carrier of claim 1, wherein: the flange forms a cylindrical member extending transverse to the outer surface of the second carrier plate; and the notches in the second carrier plate are in an inner surface of the cylindrical member.

6. The planet carrier of claim 1, wherein: the first carrier plate is made of a powder metal.

7. The planet carrier of claim 1, wherein: the legs are made of a powder metal.

8. The planet carrier of claim 1, wherein: the legs are integrally formed with the first carrier plate, the legs and the first carrier plate are formed of a non-powder metal; and the legs are brazed to the second carrier plate.

9. The planet carrier of claim 1, comprising: each of the legs having an outer surface; and the outer surface of at least one of the legs having at least one concave surface.

10. A planet carrier for use in an epicyclic gear system, comprising: a first base plate portion; a second base plate portion; a third base plate portion; the third base plate portion interconnecting the first base plate portion and the second base plate portion; the second base plate portion including a carrier plate having an outer surface, an inner surface, and an outer peripheral surface; a flange extending transverse to the outer surface of the carrier plate, the flange and the outer surface of the carrier plate forming a void; a plurality of notches formed in the carrier plate, the notches being within the void; and the carrier plate being made of a powder metal.

11. The planet carrier of claim 10, comprising: the first base plate portion and the third base plate portion being made of a non-powder metal.

12. The planet carrier of claim 10, comprising: the first base plate portion and the third base plate portion being made of a powder metal.

13. The planet carrier of claim 10, comprising: the notches having opposing engagement surfaces. ​ ​ 14. The planetary carrier of claim 10, comprising: a plurality of notches in an inner surface of the carrier plate; and the third base plate portion contacts the notches in the inner surface of the carrier plate.

15. The planetary carrier of claim 10, comprising: a plurality of notches in an inner surface of the carrier plate; the third base plate portion comprises a plurality of legs that contact the notches in the inner surface of the carrier plate; and the legs are brazed to the carrier plate.

16. The planetary carrier of claim 10, comprising: the third base plate portion comprises a plurality of legs, each of the legs having an outer surface; and the outer surface of at least one of the legs has at least one concave surface.

17. The planetary carrier of claim 10, comprising: the first base plate portion comprises a plurality of legs, each of the legs having an outer surface; and the outer surface of at least one of the legs has at least one concave surface.

18. The planetary carrier of claim 14, comprising: the third base plate portion comprises a plate portion having a first side surface and a second side surface; a plurality of notches in the first side surface of the plate portion; a plurality of legs extending from the second side surface of the plate portion, the legs contacting the notches in an inner surface of the carrier plate; and the legs are fixed to the carrier plate.

19. A power transmission assembly, comprising: a planetary gear set having a sun gear, planet gears, and a planetary carrier; the planetary carrier having a first carrier plate and a second carrier plate; the second carrier plate having an outer surface and a flange portion extending axially from the outer surface, the flange portion and the outer surface forming a void; a plurality of notches formed in the outer surface of the second carrier plate, the notches being bounded by the flange portion and located within the void; a coupler assembly comprising a locking element, the coupler assembly being disposed in the void, wherein the locking element is deployed to engage the notches in the outer surface of the second carrier plate; and the second carrier plate is made of a powder metal.

20. The power transmission assembly of claim 19, comprising: a plurality of legs connected to and extending between the first carrier plate and the second carrier plate; and the plurality of legs and the first carrier plate are made of a powder metal.

Images