Planet Carrier Radial Weld Joint for Faster Assembly
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Solution Overview
Problem
Existing planet carrier assembly designs require complex welding head movements and longer cycle times due to axial weld seams, which complicate the welding process and increase tooling costs when producing identical carrier side plates.
Innovation Solution
The carrier side plates and shaft are materially bonded at a radial joining zone, allowing the welding head to be fed perpendicularly to the axis of rotation, eliminating the need for pivoting and simplifying the welding process, while also enabling cost-effective production with shared tooling for identical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If axial weld seams are used in existing planet carrier assembly designs, then the carrier side plates can be bonded to the shaft, but the welding head requires complex movements and longer cycle times
Solution Approach 1:
The patent changes the welding direction from axial (parallel to shaft axis) to radial (perpendicular to shaft axis). The joining zone is formed in a radial plane that is penetrated perpendicularly by the axis of rotation, allowing the welding head to feed directly radially without pivoting movements, thereby reducing cycle time while maintaining bonding strength
2Strength
If axial weld seams are used in existing planet carrier assembly designs, then the carrier side plates can be bonded to the shaft, but the welding process becomes more complex and tooling costs increase
Solution Approach 1:
By transitioning to radial welding, the patent eliminates the need for complex pivoting mechanisms and multi-axis positioning required for axial welding. The welding head feeds directly in the radial direction, simplifying the welding device design and reducing tooling costs while maintaining the bonding strength between identical carrier side plates
Solution Approach 2:
The radial joining zone design allows the same welding setup to be used for bonding both identical carrier side plates to the shaft, eliminating the need for different welding procedures or tooling configurations that would be required for axial welding of multiple plates
Data Source
AI summary
A planet carrier assembly includes a shaft and a planet carrier with a first carrier side plate. The shaft includes an axially aligned axis of rotation, a guide surface, and an axial stop axially adjacent to the guide surface. The first carrier side plate is materially bonded to the shaft at a first joining zone formed axially between the axial stop and the first carrier side plate. The first carrier side plate has a holder radially supported on the guide surface and centered on the axis of rotation. The guide surface may run in a circumferential direction around the axis of rotation. The guide surface may have at least a section of an external cylindrical surface.