Differential Ring Gear Welding Geometry for Deep Laser Joining
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Solution Overview
Problem
Conventional methods for manufacturing differential devices face challenges in ensuring welding strength and position accuracy due to gas generation during laser welding, which can lead to unsatisfactory welding quality and difficulty in irradiating the laser parallel to the clearance, making it hard to weld to the deep end of the welding portion.
Innovation Solution
A manufacturing method involving a differential case and ring gear with specifically designed abutting and welding surfaces, where a separation portion with a non-linear shape is formed to allow gas discharge and ensure the energy beam stays within the welding area, preventing it from hitting the abutting surfaces and allowing deep-end welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a clearance is provided in the welding portion and welding is performed by laser welding with a welding wire inserted in the clearance, then gas discharge is improved and welding quality is enhanced, but the laser cannot be irradiated in parallel to the clearance and welding strength cannot be ensured
Solution Approach 1:
The patent introduces a multi-dimensional structure by forming both a clearance (radial dimension) and a groove (axial dimension) in the welding portion. The groove extends in the axial direction of the laser beam, creating a three-dimensional gas discharge pathway that allows the laser to be irradiated parallel to the groove while effectively discharging welding gas, thereby resolving the contradiction between welding quality and welding strength.
Solution Approach 2:
The welding portion is segmented into multiple functional regions: the clearance for wire insertion, the groove for gas discharge, and the welding area for material fusion. This segmentation allows each region to perform its specific function optimally, with the groove specifically designed to channel welding gas away from the molten pool while maintaining laser access.
2Object-generated harmful factors
If the laser is irradiated inclined with respect to the clearance direction, then gas can be discharged during welding, but it is difficult to weld to the deep end of the welding portion and welding strength cannot be ensured
Solution Approach 1:
The groove structure adds an axial dimension to gas discharge, allowing welding gas to be channeled out along the axial direction while the laser beam travels parallel to the groove. This eliminates the need for inclined laser irradiation and enables deep-end welding with full welding strength.
3Strength
If the differential case and differential ring gear are fastened by a bolt, then the connection strength is ensured, but the size increases which prevents size reduction
Solution Approach 1:
The patent replaces the mechanical bolt connection system with a laser welding system. The welding portion is formed with a groove structure that enhances laser welding effectiveness, eliminating the need for bolts and thereby reducing the overall size of the differential device while maintaining connection strength through metallurgical bonding.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method improves welding quality by preventing gas from dissolving in the welding portion, ensuring strong and accurate welding, and maintaining position accuracy of the differential ring gear.
Implementation Method 1
welded by the energy beam on an outer peripheral side of the differential case
Implementation Method 2
irradiating the energy beam to the welding portion
Data Source
AI summary
A first abutting surface, a first welding surface, a first facing surface are formed in a differential case. A second abutting surface, a second welding surface, and a second facing surface are formed in a differential ring gear. In an installing step, the first abutting surface and the second abutting surface are inserted, positions of the differential case and the differential ring gear are determined in an axial direction, a separation portion that spaces the first welding surface and the second welding surface away from each other and that has a non-linear portion is formed, and a void is formed between the first facing surface and the second facing surface. In a welding step, a laser is irradiated to the separation portion and the first welding surface and the second welding surface are welded.