Electromagnetic Pulse Welded Drivetrain Assembly for Lower Weight
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current vehicle drivetrain assemblies face challenges in achieving a balance between durability and weight reduction, as they typically require heavy steel components for durability but lack efficient methods for integrating lighter materials effectively.
Innovation Solution
The use of an aluminum torque transmitting member with an annular planar plate and a steel torque transmitting member connected via an electromagnetic pulse weld, which forms a strong bond along a radial direction, allowing for a durable yet lighter drivetrain assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy steel components are used for durability, then strength and reliability are improved, but weight increases
Solution Approach 1:
The drivetrain assembly uses a composite structure combining aluminum alloy (lightweight) for the clutch hub and steel (strong) for the sun gear and ring gear. This composite material approach allows each component to be made from the material best suited for its specific function, achieving overall strength while minimizing weight.
Solution Approach 2:
The drivetrain assembly is segmented into distinct aluminum and steel components that are selectively joined. The aluminum clutch hub is separated from the steel sun gear and ring gear, allowing each segment to be optimized for its specific requirements (weight vs. strength) while maintaining overall assembly integrity through electromagnetic pulse welding.
2Weight of moving object
If aluminum and steel components are joined, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent replaces traditional mechanical joining methods (such as bolts, rivets, or interference fits) with electromagnetic pulse welding. This substitution simplifies the manufacturing process by eliminating the need for complex alignment fixtures, multiple fastening operations, and post-assembly adjustments, while achieving strong metallurgical bonds between dissimilar metals.
Solution Approach 2:
The electromagnetic pulse welding process utilizes controlled changes in electrical current parameters (pulse duration, amplitude, and timing) to achieve precise welding of aluminum to steel. By controlling these parameters, the process manages the complexity of joining dissimilar metals with different thermal and electrical properties, ensuring reliable bonds without excessive manufacturing complexity.
3Strength
If electromagnetic pulse weld is applied progressively along radial direction, then weld strength is improved, but manufacturing time increases
Solution Approach 1:
The electromagnetic pulse welding is applied in a progressive, periodic manner around the radial direction of the clutch hub. Multiple pulse welds are applied at different angular positions sequentially, creating a series of strong weld zones that collectively secure the aluminum hub to the steel components. This periodic application of welding energy achieves comprehensive joint strength while managing heat input and process time.
Solution Approach 2:
The welding positions are pre-positioned around the radial direction of the clutch hub, allowing for systematic and efficient application of electromagnetic pulses. By planning the weld sequence in advance along predetermined radial locations, the process optimizes the balance between achieving sufficient weld strength and minimizing total welding time through efficient path planning.
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
This solution provides a durable drivetrain assembly with reduced weight by effectively bonding aluminum and steel components, enhancing the assembly's structural integrity while minimizing material mass.
Implementation Method 1
An electromagnetic pulse weld forms and connects the plate portion of the first torque transmitting member around its round opening with the connection location of the second torque transmitting member
Data Source
AI summary
A vehicle drivetrain assembly, and method for making the assembly, including first and second torque transmitting members, one of which is made of aluminum and the other of which is made of steel, and being joined by an electromagnetic pulse weld progressively applied along a radial direction relative to a central axis of the assembly.