Hybrid Drum and Gear Assembly for Lightweight Torque Transfer
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Solution Overview
Problem
Automatic transmission systems require torque transmitting assemblies that minimize weight, cost, and complexity while maximizing rigidity and efficiency, with enhanced interlocking and coupling of components, which existing designs fail to achieve effectively.
Innovation Solution
A torque transmitting assembly comprising a drum with splines and teeth, coupled with a gear assembly including an annular gear and a steel plate, where the drum is formed from aluminum and the gear from steel, allowing for intermeshing teeth and splines to enhance coupling and reduce the need for additional components, thereby minimizing material usage and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If complex torque transmitting assemblies are designed to serve multiple functions, then the number of components is reduced, but the materials must accommodate greatest stresses making the assembly heavier
Solution Approach 1:
The torque transmitting assembly is divided into separate functional components: an aluminum drum for weight reduction and a steel gear assembly for strength. This segmentation allows each component to be optimized for its specific function rather than requiring the entire assembly to be made from heavy-duty materials.
Solution Approach 2:
The invention uses composite construction by combining aluminum (for the drum) and steel (for the gear assembly) to create a hybrid structure. This allows the assembly to achieve both weight reduction from aluminum and structural strength from steel, resolving the contradiction between weight and multi-functionality.
2Weight of moving object
If aluminum is used in place of steel to reduce weight, then weight is minimized, but aluminum is not appropriate for components requiring high strength like annulus gears
Solution Approach 1:
Different materials are assigned to different locations based on local requirements: aluminum is used for the drum where weight is critical, while steel is used for the gear assembly where high strength is required. This local differentiation resolves the contradiction by matching material properties to functional demands.
Solution Approach 2:
The hybrid aluminum-steel construction allows the assembly to achieve both weight reduction from aluminum and structural strength from steel, resolving the contradiction between weight and strength requirements.
3Stability of the object's composition
If additional components are added to enhance interlocking and coupling, then rigidity and efficiency are improved, but weight, cost, and complexity increase
Solution Approach 1:
The gear assembly is merged with the drum through direct engagement of interlocking features. The steel gear assembly integrates with the aluminum drum, eliminating the need for separate coupling components while maintaining rigidity and structural integrity.
Solution Approach 2:
The gear assembly serves multiple functions simultaneously: it provides torque transmission, structural support, and interlocking engagement. This multi-functionality reduces the need for additional specialized components, maintaining rigidity without increasing complexity.
Data Source
AI summary
A torque transmitting assembly including a first drum having a plurality of teeth formed at an end thereof and a sensor component annularly extending on an inner surface of the first drum. A gear assembly axially aligns with the first drum and has a plurality of teeth intermeshing with the plurality of teeth of the drum. The gear assembly includes an annular gear and a plate axially aligning with the gear.