Planet Carrier Flange Interlock to Replace Welding
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Solution Overview
Problem
Existing planet carrier assembly connection methods, such as welding, are costly, energy-intensive, and can lead to distortion, weld spatter, and require expensive equipment, while also necessitating complex preparation and post-processing, which are not efficiently addressed by prior art.
Innovation Solution
A planet carrier assembly where the carrier flange and carrier are connected via form-fit or interlocking driver elements with undercuts, allowing for a non-detachable connection produced through cold forming processes like stamping, embossing, and extrusion, eliminating the need for welding and associated tools and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the carrier flange and carrier, then a strong and non-detachable connection is achieved, but the production cost increases, energy consumption increases, and distortion and weld spatter occur
Solution Approach 1:
The patent replaces the welding process (thermal/chemical connection) with a mechanical interlocking system consisting of driver elements with undercuts and corresponding receptacles. This mechanical connection achieves comparable strength without the harmful effects of welding, directly resolving the contradiction between connection strength and manufacturing ease/cost.
2Strength
If welding is used to connect the carrier flange and carrier, then a strong and non-detachable connection is achieved, but energy consumption increases
Solution Approach 1:
The patent eliminates the welding process entirely by using a mechanical interlocking system. The driver elements with undercuts engage with receptacles in the carrier flange through purely mechanical means, requiring no external energy input for heating or melting, thus resolving the contradiction between connection strength and energy consumption.
3Strength
If welding is used to connect the carrier flange and carrier, then a strong and non-detachable connection is achieved, but distortion and weld spatter occur
Solution Approach 1:
The patent replaces the thermal welding process with a cold mechanical interlocking system. The driver elements with undercuts and receptacles create a strong connection through mechanical engagement only, completely avoiding the thermal effects that cause distortion and weld spatter, thus resolving the contradiction between connection strength and harmful factors.
4Strength
If welding is used to connect the carrier flange and carrier, then a strong and non-detachable connection is achieved, but complex preparation and post-processing are required
Solution Approach 1:
The patent replaces welding with a mechanical interlocking system that integrates the connection features directly into the molded components. The driver elements and receptacles are formed as integral parts during injection molding, eliminating the need for separate preparation and post-processing steps required by welding, thus resolving the contradiction between connection strength and process complexity.
5Ease of manufacture
If cold forming processes are used to produce the shaft-hub connection, then production cost decreases and energy consumption decreases, but the connection must be strong enough to replace welding
Solution Approach 1:
The patent employs curved undercut geometries in the driver elements that engage with corresponding receptacles. The curved geometry of the undercuts creates a wedging action during assembly that generates high contact pressures and friction, enabling the cold-formed mechanical connection to achieve strength comparable to welding while maintaining low production costs.
Solution Approach 2:
The driver elements with undercuts and receptacles are pre-formed as integral parts of the carrier and carrier flange during injection molding. This preliminary formation of the connection features eliminates the need for subsequent welding operations, allowing cold forming processes to achieve both cost reduction and sufficient connection strength.
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 solution enables cost-effective and energy-efficient production of planet carrier assemblies with reduced distortion and spatter risks, utilizing existing manufacturing equipment and avoiding the need for costly welding systems, while ensuring a strong and reliable connection.
Implementation Method 1
allowing for a non-detachable connection produced through cold forming processes like stamping, embossing, and extrusion
Implementation Method 2
The convex contour is axially engaged from the rear at two positions pointing away from each other axially by two axially opposite projections on the concave contour, each of which forms an axial fixing means in one of the axial directions. The projections are formed from plastically displaced material of the driver element
Data Source
AI summary
A planet carrier assembly includes a rotational axis, a carrier and a carrier flange. The carrier has circumferentially spaced first driver elements formed thereon and the carrier flange has circumferentially spaced second driver elements formed thereon. The second driver elements are interconnected with the first driver elements at common contact areas in an interlocking manner. The carrier flange is axially secured to the carrier in an axial direction by plastically deformed material at the common contact areas. In an example embodiment, the plastically deformed material is displaced from the first driver elements or the second driver elements.