Integrated Pinion Carrier Disc for Automatic Transmission Weight Reduction
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Solution Overview
Problem
Conventional pinion carriers used in automatic transmissions are heavy due to the need for additional material to hold overrunning control elements together, limiting weight reduction opportunities in automotive components.
Innovation Solution
An integrated one-piece pinion carrier disc with an overrunning control element, featuring ring segments, spacers, and retention elements formed from sintered powdered metal, eliminating the need for mechanical connections and allowing material removal between pinions while maintaining structural integrity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional separate pinion carrier and overrunning control element design is used, then structural continuity and reliability are maintained, but weight is increased due to additional material needed to hold control elements together
Solution Approach 1:
The patent combines the pinion carrier and overrunning control element into a single integrated component. The pinion carrier body directly forms the outer race of the overrunning clutch, eliminating the need for separate mounting structures and reducing overall weight while maintaining structural integrity through the integrated design
2Weight of moving object
If material is removed between pinions in conventional design, then weight is reduced, but structural continuity and reliability are compromised
Solution Approach 1:
By integrating the control element with the pinion carrier, the design allows material removal between pinions without creating weak points. The integrated structure ensures that remaining material is optimally distributed and structurally sound, maintaining reliability while achieving weight reduction
3Weight of moving object
If integrated one-piece design is used, then weight is reduced and structural continuity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs sintering parameters and material properties to enable the integrated design. By controlling sintering density, porosity, and material composition, the manufacturing process achieves the complex integrated geometry while maintaining production feasibility and component reliability
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 integrated design achieves weight savings by reducing material usage without compromising structural continuity or service life, with only one joint and less lash, enabling lighter motor vehicle components.
Implementation Method 1
An integrated one-piece pinion carrier disc with an overrunning control element, featuring ring segments, spacers, and retention elements formed from sintered powdered metal
Data Source
AI summary
A pinion carrier includes a first disc including ring segments, each ring segment extending angularly about an axis and spaced angularly from the other ring segments, a second disc, spacers secured to the discs and separating the discs axially, and retention elements, each retention element secured to one of the ring segments.