Planetary Gear Carrier Layout for Higher Torque and Lower Noise
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Solution Overview
Problem
The existing planetary gear apparatus faces challenges in reducing component costs and increasing torque capacity while minimizing noise, due to the complexity and cost associated with forming multiple shaft holes for pinion gears, which also affects structural reliability.
Innovation Solution
The design incorporates single and double pinion gears with a planet carrier unit that includes multiple carriers with strategically positioned shaft holes and oil holes, allowing for independent rotation of pinion gears and improved lubrication, reducing the number of components and enhancing torque capacity while forming a reliable structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple shaft holes are formed in the common carrier to accommodate double pinion shafts and single pinion shafts, then the pinion gears can be properly supported and rotated, but the number of components and component costs increase
Solution Approach 1:
The patent combines multiple pinion shafts (both double pinion shafts and single pinion shafts) onto a single common carrier by forming an integrated shaft hole structure. Instead of using separate carriers for different pinion types, the invention merges them into one carrier with a unified shaft hole configuration that accommodates all pinion shafts, thereby reducing component count while maintaining structural reliability
Solution Approach 2:
The common carrier is designed with multi-functionality to serve both double pinion shafts and single pinion shafts simultaneously. The shaft hole structure is configured to universally support different types of pinion gears (double outer, double inner, and single pinion gears) on the same carrier, eliminating the need for separate specialized carriers for each pinion type
2Reliability
If three or more shaft holes are formed in the common carrier to increase the number of pinion gears, then the support structure reliability and noise reduction improve, but it becomes difficult to form the shaft holes and impossible to increase pinion gears
Solution Approach 1:
The patent segments the shaft hole formation process into multiple sequential drilling operations. Instead of attempting to form all shaft holes in a single complex operation, the invention drills shaft holes one by one in sequence, making the manufacturing process feasible and manageable while still achieving the desired number of pinion gears (three or more) for improved reliability and noise reduction
3Quantity of substance
If nine shaft holes are formed in the common carrier to accommodate three single pinion gears, three double inner pinion gears, and three double outer pinion gears, then all required pinion gears can be disposed, but the component cost increases
Solution Approach 1:
The patent merges the support structure for all nine pinion gears (three single, three double inner, and three double outer) into a single common carrier with an integrated shaft hole configuration. This consolidation reduces the total number of carriers and associated components needed, thereby lowering component costs while still accommodating the full complement of pinion gears required for the planetary gear assembly
Data Source
AI summary
A planetary gear apparatus includes single pinion gears, double pinion gears comprising first double pinion gears and second double pinion gears, a planet carrier unit surrounding the single pinion gears, the first double pinion gears, and the second double pinion gears, first pinion shafts coupled to the planet carrier unit, the single pinion gears being rotatably mounted on the first pinion shafts, and one of the first double pinion gears and the second double pinion gears being rotatably mounted on the first pinion shafts, and second pinion shafts coupled to the planet carrier unit, wherein the other of the first double pinion gears and the second double pinion gears are mounted on the second pinion shafts.