Planetary Carrier Bridge Plate Structure for Lower Material Waste
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Solution Overview
Problem
Conventional planetary carriers face challenges in reducing material cost and ensuring strength due to complex planar shapes and high material waste, with existing solutions either failing to minimize material usage effectively or compromising on strength through clinching methods.
Innovation Solution
A planetary carrier design featuring a first and second supporting plate with a simplified polygonal shape and bridge plates that connect them via welding, reducing material size and waste while enhancing structural integrity by distributing shear forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the carrier plate has a complicated planar shape with leg portions extended radially, then the planetary carrier can support multiple pinion shafts, but the size of base material increases and material yield deteriorates
Solution Approach 1:
The planetary carrier is divided into multiple separate plate members (first plate member, second plate member, third plate member) instead of using a single complicated carrier plate. Each plate member has a simpler planar shape and can be manufactured separately from smaller base materials, reducing material waste while collectively providing the same functional support for multiple pinion shafts
Solution Approach 2:
The multiple plate members are arranged and connected in a nested configuration where the first plate member supports one end of pinion shafts, the second plate member supports the other end, and the third plate member connects them. This nested arrangement allows each component to be optimized independently while achieving the overall structural requirement
2Ease of manufacture
If stud pins are fixed to carrier members by clinching, then welding is avoided, but the strength of the planetary carrier is insufficient
Solution Approach 1:
The connection method is merged from a single clinching operation to a combination of clinching and welding. The pinion shafts are first fixed to the plate members by clinching, and then the plate members themselves are welded together at their overlapping portions, creating a hybrid connection system that provides both ease of assembly and high strength
Solution Approach 2:
The connection system uses a composite approach combining two different joining methods (mechanical clinching and thermal welding) to achieve properties that neither method alone could provide. The clinching provides initial fixation and alignment, while welding provides ultimate strength and rigidity
3Strength
If bridge plates are welded to connect supporting plates, then the strength is ensured, but the number of welding spots increases and working cost increases
Solution Approach 1:
Welding is applied selectively only at the overlapping portions of the plate members where structural strength is most critical, rather than throughout the entire assembly. This localized welding approach ensures strength where needed while minimizing the number of welding spots and associated costs
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 significantly reduces material costs and improves strength by minimizing material usage and optimizing the number of welding spots, ensuring robustness against rotational shear forces while maintaining efficient manufacturing processes.
Implementation Method 1
one end of each of which is joined to the first supporting plate via a welding portion and the other end of each of which is joined to the second supporting plate via a welding portion
Data Source
AI summary
A planetary carrier includes a plurality of pinion gears, a plurality of pinion shafts that are each inserted in the corresponding pinion gear, a first supporting plate that supports one end of each of the pinion shafts, a second supporting plate that supports the other end of each of the pinion shafts, and a plurality of bridge plates, one end of each of which is joined to the first supporting plate via a welding portion and the other end of each of which is joined to the second supporting plate via a welding portion and which connects the first and second supporting plates.