Modular Welded Transmission Housings for Lower Material Use
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Solution Overview
Problem
Industrial transmission manufacturing involves high material and energy expenditure, particularly in cast constructions, and there is a need for more efficient and standardized methods to reduce these costs while maintaining performance.
Innovation Solution
A computer-assisted method for creating welded constructions, utilizing a partly variable construction kit that includes standardized and variable parts, allowing for optimized material use and energy efficiency by selecting parts based on individual construction-specific input parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cast constructions are used for industrial transmissions, then structural strength and durability are improved, but material usage and energy consumption increase significantly
Solution Approach 1:
The transmission housing is divided into multiple standardized modules (e.g., housing sections, end covers, intermediate covers) that can be separately manufactured and assembled. This segmentation enables the use of welded construction instead of monolithic casting, reducing material usage while maintaining structural integrity through optimized joinery of parts.
Solution Approach 2:
The invention changes the construction parameter from monolithic casting to modular welded assembly. This parameter change allows for more efficient material utilization by only producing the necessary structural elements and joining them, rather than casting entire housing sections as single pieces, thereby reducing material consumption and energy expenditure.
2Loss of substance
If welded constructions are used instead of cast constructions, then material and energy savings are achieved, but construction complexity and standardization requirements increase
Solution Approach 1:
The invention develops a universal construction kit of standardized modules that can be used across different transmission models and variants. These standardized housing sections, end covers, and intermediate covers serve multiple functions and can be combined in various configurations, reducing construction complexity through reuse of proven designs while maintaining material savings.
Solution Approach 2:
By changing from custom-designed welded constructions to standardized modular components, the invention reduces construction complexity. The standardized modules have pre-optimized designs, connection interfaces, and manufacturing parameters, simplifying the overall construction process despite using welded assembly instead of casting.
3Adaptability or versatility
If customized transmission housing variants are produced for small runs, then individual customer requirements are met, but production efficiency and standardization decrease
Solution Approach 1:
The housing is segmented into standardized modules that can be selectively combined to create customized variants. This allows small production runs with high customization capability, as different combinations of the same standardized modules can satisfy individual customer requirements without requiring entirely custom designs, thereby maintaining production efficiency.
Solution Approach 2:
The modular construction system enables dynamic configuration of transmission housing variants by selectively assembling different standardized modules based on customer requirements. This dynamic adaptability allows efficient production of customized variants for small runs while maintaining the benefits of standardized component manufacturing.
4Strength
If large-area solid sheets and flame-cut parts are used in welded constructions, then structural integrity is ensured, but offcut material and CO2 emissions increase
Solution Approach 1:
Instead of using large-area solid sheets that require extensive flame-cutting and generate significant offcuts, the invention segments the housing into multiple smaller standardized modules. These modules can be manufactured from smaller material pieces with less waste, and their assembly through welding achieves the required structural integrity without the need for large-scale material removal.
Data Source
AI summary
In a method for providing a welded construction generated in an at least partially computer-assisted manner, especially for industrial transmission, an individual construction-specific input parameter of at least part of the welded structure is defined manually and/or with computer assistance from build size parameter, terminal fit parameter, and build shape parameter. A database includes a partly variable construction kit in which at least two standardized parts are recorded, with one of the at least two standardized parts being selected in a computer-assisted manner to form the welded construction. The welded construction is generated in a computer-assisted manner using the selected one of the at least two standardized parts and taking into account of the individual construction-specific input parameter.