Planetary Carrier Plate Staking for Precise Parallel Alignment
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Solution Overview
Problem
Existing methods for assembling planetary carrier assemblies often result in misalignment of parallelism between plate carrier elements, leading to inoperable components and increased scrap rates due to shifting alignment, which is not effectively addressed.
Innovation Solution
A method involving the formation of staking elements on the legs of a second carrier plate, which are fixed into a first carrier plate using an axial load, followed by welding at the interface to ensure precise alignment and prevent deformation, utilizing an axial load of 1-8 kN to secure the plates without causing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If known techniques are used to connect plate carrier elements, then assembly can be performed, but parallelism alignment shifts out of alignment causing inoperable components and increased scrap rates
Solution Approach 1:
The method applies preliminary action by forming staking elements on the legs of the second carrier plate before assembly, and applying axial load during assembly to dig these staking elements into the first carrier plate. This preliminary preparation of staking elements ensures precise parallelism alignment is achieved and maintained during the assembly process, preventing the alignment shifts that cause inoperable components and reduced scrap rates
2Manufacturing precision
If axial load is applied to fix carrier plates together, then precise alignment is achieved, but deformation may occur without proper control
Solution Approach 1:
The staking elements are formed in advance on the legs before assembly, preparing the structure to receive and distribute the axial load properly. This preliminary formation ensures that when axial load is applied during assembly, the force is distributed through the staking elements digging into the first carrier plate, achieving precise alignment while preventing deformation through controlled force distribution
Solution Approach 2:
The method controls the parameters of axial load application and staking element geometry to optimize the balance between achieving precise alignment and preventing deformation. By adjusting parameters such as staking element dimensions, axial load magnitude, and material properties, the process achieves manufacturing precision while maintaining structural integrity of the assembled carrier plates
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 method ensures precise alignment and prevents deformation, maintaining the required tolerances, reducing scrap rates and ensuring the planetary carrier assembly operates effectively by embedding staking elements into the first carrier plate during assembly.
Implementation Method 1
application of an axial load such that the at least one staking element on the at least one of the plurality of legs digs into or otherwise is fixed to the first carrier plate
Implementation Method 2
welding an area defined at an interface between the plurality of legs and the first carrier plate. The welding step can be configured to consume the staking element
Data Source
AI summary
A method of forming a planetary carrier assembly is disclosed herein. In one aspect, the method includes providing a first carrier plate and a second carrier plate. The first carrier plate has a first body portion, and the second carrier plate has a second body portion including a plurality of legs. The method includes forming at least one staking element on an axial end of at least one of the plurality of legs. The method includes fixing the first carrier plate and the second carrier plate to each other via application of an axial load such that the at least one staking element on the at least one of the plurality of legs digs into the first carrier plate.