Segmented Input Drum Assembly for High-Torque Transmissions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The single piece machined input drums in 'factory installed' automotive transmissions, such as those in the '4L60', '4L60E', '4L65E', '4L70E', '700', and '700R4' transmissions, fail due to weak areas at the hub to clutch cylinder and input shaft spline, especially under increased torque and horsepower.
Innovation Solution
A two or three piece input drum design is introduced, where the hub and clutch cylinder are formed from different materials like steel and aluminum, with outwardly extending tabs and internal grooves for secure assembly, enhancing strength and rotational energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single piece machined drum is used, then the structure is simple and manufacturing is easier, but the strength is insufficient under increased torque and horsepower
Solution Approach 1:
The single piece drum is divided into multiple separate components: a drum shell and a hub assembly. The hub assembly includes an input shaft spline area and clutch cylinder, while the drum shell provides the outer structure. These components are assembled together using tabs and grooves, allowing each part to be optimized for its specific function while collectively providing the required strength under increased torque and horsepower conditions.
2Use of energy by moving object
If a single piece drum is used, then manufacturing is simpler, but the efficiency of rotational energy transfer is reduced
Solution Approach 1:
By separating the drum into a hub assembly and drum shell, the design enables more efficient rotational energy transfer. The hub assembly with its optimized spline area and clutch cylinder can be precisely engineered for energy transfer, while the drum shell provides structural support. The tab-and-groove connection ensures efficient torque transmission from the hub to the drum shell, reducing energy losses compared to a single piece design.
3Reliability
If the drum is made from a single material, then manufacturing is easier, but the performance under high torque and horsepower is insufficient
Solution Approach 1:
The drum employs different materials for different components: the drum shell is made from aluminum casting while the hub assembly uses steel or high strength aluminum. This composite approach allows each component to be made from the material best suited for its specific requirements - the aluminum shell provides weight savings and corrosion resistance, while the steel or high strength aluminum hub provides the necessary strength for withstanding high torque and horsepower conditions.
Data Source
AI summary
An input drum of an automotive transmission for motor vehicles is formed from a plurality of components assembled together. The input drum has a hub having outwardly extending tabs, and a clutch cylinder having internal grooves for receiving the tabs when the hub is assembled to the clutch cylinder. The hub and the clutch cylinder are arranged such that openings in the hub and openings in an inwardly extending circumferential flange of the clutch cylinder are in axial alignment when the tabs of the hub are received in the internal grooves of the clutch cylinder. The hub and clutch cylinder are assembled together by connecting elements extending through the aligned openings in the hub and clutch cylinder. An input shaft is permanently or removably attached to the hub.


