Composite Planet Carrier for High Torque Actuator
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Solution Overview
Problem
Existing planetary gears in motor vehicle actuators face deformation issues with plastic planet carriers under high torque conditions, leading to potential damage and misalignment with the transmission housing, while an all-metal design is impractical due to forming limitations and an all-plastic design fails to transmit sufficient torque.
Innovation Solution
A planetary gear design featuring a metal planet holder with a plastic connecting means that completely encloses it, providing increased rigidity and ensuring torque transmission without damaging the connecting means, allowing for high torque transmission while maintaining stability and reducing the risk of deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the planet carrier is made of plastic, then the manufacturing cost is reduced and ease of manufacture is improved, but the rigidity and torque transmission capability deteriorate under high torque conditions
Solution Approach 1:
The planet carrier is constructed as a composite component with a metal planet holder providing structural strength and rigidity, combined with a plastic connecting means that encloses the planet holder. This composite structure enables the carrier to transmit high torques while maintaining manufacturing advantages of plastic components.
2Device complexity
If the planet carrier is made of plastic, then the manufacturing complexity is reduced, but the stability and resistance to deformation worsen under high torque
Solution Approach 1:
The composite design combines a metal planet holder for stability with a plastic connecting means, achieving high stability under torque while keeping the overall structure relatively simple and maintaining manufacturing advantages.
3Strength
If an all-metal planet carrier is used, then the torque transmission capability and strength are improved, but the forming technology and manufacturing feasibility deteriorate
Solution Approach 1:
Instead of creating a complex all-metal carrier, the invention uses a composite structure where only the critical load-bearing planet holder is made of metal, while the connecting means is made of plastic, achieving high strength while maintaining manufacturing feasibility.
4Reliability
If the planet carrier is made of plastic, then the cost is reduced, but the risk of damage to the connecting means under high torque increases
Solution Approach 1:
The composite structure with metal planet holder and plastic connecting means optimizes the distribution of mechanical stresses, protecting the connecting means from damage while maintaining cost-effectiveness compared to all-metal designs.
Data Source
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AI summary
The invention relates to a planetary gear set for a motor vehicle actuator with a planet carrier. The planet carrier has a planet holder for holding planet gears and a connecting element, non-rotatably connected to the planet holder, for connecting the planet holder to an output shaft. The planet holder is made of a stiffer material than the connecting element.