Single-Plate Planet Carrier With Grooved Shaft Support
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Solution Overview
Problem
Current planet carriers for differential reduction brake actuators face challenges in facilitating the assembly of satellites and are costly to manufacture, with a need to minimize weight and optimize operation and reliability.
Innovation Solution
A planet carrier design featuring a cylindrical casing with radial openings and longitudinal grooves to support rotational guide shafts, allowing for easier assembly and manufacturing, made from a single plate with constant thickness, and produced through processes like stamping or molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional planet carrier is machined or sintered with tubular structure, then the structural strength is ensured, but the manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The invention merges multiple functions into a single plate structure: the plate forms the cylindrical casing, creates radial openings for satellite insertion, and generates longitudinal grooves for guide shaft support through deformation. This consolidation eliminates the need for separate tubular structures and reduces the number of manufacturing steps, directly addressing the contradiction between manufacturing ease and device complexity.
Solution Approach 2:
The invention changes the physical state and geometry of the plate through deformation to create functional grooves. By deforming the plate along lines crossing the openings, longitudinal grooves are formed that support guide shafts. This parameter change approach transforms a simple plate into a complex functional structure without requiring complex manufacturing processes, resolving the contradiction between ease of manufacture and device complexity.
2Ease of operation
If a single plate is deformed to form longitudinal grooves, then the assembly of satellites is facilitated, but the manufacturing precision requirements increase
Solution Approach 1:
The invention segments the plate deformation process into discrete lines crossing each opening. By defining specific deformation lines rather than continuous complex surfaces, the manufacturing process becomes more controllable and precise. Each line deformation creates a consistent groove geometry, facilitating satellite assembly while managing precision requirements through segmented, repeatable operations.
3Weight of moving object
If the planet carrier is made from a single plate with constant thickness, then the weight is minimized, but the structural strength may be compromised
Solution Approach 1:
The invention employs a thin plate structure with constant thickness to form the planet carrier, minimizing weight while maintaining structural integrity. The plate is deformed to create grooves and openings, utilizing the flexibility and strength-to-weight ratio of thin-walled structures. This approach directly addresses the contradiction by using thin-film principles to achieve lightweight construction without compromising essential structural strength.
Solution Approach 2:
The single plate structure merges multiple structural functions into one component: it provides the cylindrical casing, creates mounting openings, and forms support grooves. This consolidation eliminates the need for additional reinforcing structures that would increase weight, maintaining strength while minimizing mass through functional integration.
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 design simplifies the mounting of planet gears, reduces manufacturing costs, and enhances the operational reliability of the mechanism while maintaining minimal weight.
Implementation Method 1
The plate has a deformation producing a longitudinal groove on at least one side of the openings
Data Source
Figure 1~2b
Figure 3~5
Figure 6a~7
AI summary
The invention relates to a planet carrier comprising a framework arranged and configured to carry planet gears (30) distributed at angles about the axis (A10) of the planet carrier. The framework comprises a single plate (20) arranged and configured to form a cylindrical shell that has openings (21) through which a planet gear (30) projects radially. The plate (20) has a deformation forming a longitudinal groove (25) of at least one side of the openings, along a direction parallel to the axis of the planet carrier, so as to support one or more shafts for guiding rotation (31) projecting beyond said planet gears (30). The invention belongs to the field of braking systems for motor vehicles.