Hybrid Drivetrain Assembly Using Radial Electromagnetic Pulse Welding
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Solution Overview
Problem
Existing vehicle drivetrain assemblies face challenges in achieving a lightweight construction while maintaining durability, as they typically rely on heavy materials like steel for torque transmission.
Innovation Solution
A vehicle drivetrain assembly composed of aluminum and steel torque transmitting members joined by an electromagnetic pulse weld, applied progressively in a radial direction, to create a strong and lightweight structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel is used for torque transmitting members, then strength and durability are improved, but weight increases
Solution Approach 1:
The drivetrain assembly uses a composite construction with aluminum torque transmitting members and steel torque transmitting members joined together. The aluminum members provide lightweight properties while the steel members provide high strength, creating a composite structure that achieves both weight reduction and maintained strength performance.
2Weight of moving object
If aluminum is used for torque transmitting members, then weight is reduced, but strength and durability deteriorate
Solution Approach 1:
The patent employs composite materials by combining aluminum and steel torque transmitting members in a single drivetrain assembly. The aluminum members reduce overall weight while the steel members are strategically positioned to provide necessary strength and durability for torque transmission, resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
Different materials are assigned to different parts of the drivetrain assembly based on local requirements. Aluminum is used where weight reduction is prioritized, while steel is used in components requiring higher strength for torque transmission, achieving local optimization of material properties to resolve the weight-strength contradiction.
3Weight of moving object
If aluminum and steel members are joined, then lightweight construction is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical joining methods (such as bolting or riveting) with electromagnetic pulse welding to join aluminum and steel members. This substitution simplifies the manufacturing process by eliminating complex assembly steps, reducing the number of fasteners required, and enabling more efficient production of the hybrid drivetrain assembly.
Solution Approach 2:
The electromagnetic pulse welding process utilizes controlled electromagnetic parameters (pulse duration, energy levels, frequency) to achieve reliable joining of dissimilar metals (aluminum and steel). By optimizing these process parameters, the manufacturing complexity is managed while achieving strong, consistent welds that enable lightweight construction.
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
The solution provides a durable and lightweight drivetrain assembly by forming a strong bond between aluminum and steel members, enhancing the structural integrity and reducing weight compared to a fully steel construction.
Implementation Method 1
An electromagnetic pulse weld of the vehicle drivetrain assembly forms and connects the plate portion of the first aluminum member around its round opening with the connection location of the second steel member
Data Source
AI summary
A vehicle drivetrain assembly (10) and method for making the assembly of first and second torque transmitting members (12, 14), one of which (12) is aluminum and the other of which (14) is steel, that are joined by an electromagnetic pulse weld (16) progressively applied along a radial direction relative to the axis (A) of assembly rotation so as to provide a lightweight construction.