Anticlastic Planet Carrier Webs for Lightweight Torque Transmission
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Solution Overview
Problem
Existing planetary gears face challenges in achieving optimal performance and cost-effectiveness, particularly in terms of mechanical stress, material utilization, and weight reduction, which are not adequately addressed in current designs.
Innovation Solution
A one-piece planet carrier with anticlastic curved outer surfaces on its webs, allowing for increased mechanical resistance and reduced material usage, designed to transfer rotation between opposite cheeks with variable or constant radii, and incorporating features like lubricant channels and a compact design to accommodate multiple planet gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional flat or simply curved web designs are used in planetary carriers, then manufacturing is simpler, but mechanical strength and material utilization are insufficient
Solution Approach 1:
The web is designed with anticlastic curved outer surface that is convexly curved around a first convex axis and concavely curved around a second curved axis. This dual-curvature geometry optimizes stress distribution and material utilization, achieving high mechanical strength while maintaining manufacturability through casting processes.
2Strength
If more material is used in the planet carrier web, then mechanical strength increases, but weight increases
Solution Approach 1:
The anticlastic curved geometry with specific radii of curvature (first radius around the first convex axis, second radius around the second curved axis) optimizes the strength-to-weight ratio. This parameter optimization allows reduced material usage while maintaining required mechanical strength, achieving weight reduction without compromising structural integrity.
3Volume of moving object
If small radii are used in the web transitions, then the planet carrier is more compact, but mechanical stress increases
Solution Approach 1:
The web transitions are designed with anticlastic curvature and optimized radii of curvature to avoid stress concentrations. The dual-curvature geometry distributes mechanical stresses evenly across the web-flange transitions, preventing stress peaks while maintaining compact dimensions suitable for planetary gear applications.
4Ease of manufacture
If the planet carrier is designed as multiple separate parts, then assembly and manufacturing flexibility improve, but manufacturing complexity and cost increase
Solution Approach 1:
The planet carrier is designed as a one-piece integral structure where the hub and multiple webs are formed as a single component. This integration eliminates assembly requirements between carrier parts, reduces manufacturing complexity, and enables cost-effective production through casting processes, while the internal web geometry remains optimized for mechanical strength.
Data Source
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AI summary
The invention relates to a planetary carrier (10) comprising first and second side walls (12, 14) interconnected by a plurality of webs (16). . At least one of the webs (16) has a curved outer surface (32). According to the invention, the curved outer surface (32) is anticlastic in at least one region (35). The invention further relates to a planetary gear (60) equipped with a corresponding planetary carrier (10) and to a drive train (70) comprising said type of planetary gear (60). Similarly, the invention relates to a wind turbine (80) in which a corresponding drive train (70) is used. Similarly, the invention relates to an industrial application (90) having a planetary gear (60) in which a claimed planetary carrier (10) is used.