Stacked Planetary Gear Carrier Assembly Manufacturing
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Solution Overview
Problem
Existing methods for assembling planet carrier assemblies in stacked planetary gear sets are costly, large, and heavy, failing to optimize construction and machining processes effectively.
Innovation Solution
A method involving the formation and attachment of inner and outer spiders to a back plate using techniques like brazing, welding, staking, or rolling, with the spiders potentially formed from powdered metal by precision casting or stamping, to create a carrier assembly that reduces size and weight, and includes precision machining of pinion holes and securement of planet gears and pins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining methods are used to form spider carriers, then structural integrity is maintained, but construction and machining costs increase
Solution Approach 1:
The patent changes the manufacturing method from traditional machining to alternative processes such as casting, forging, or additive manufacturing. This parameter change in the formation process reduces construction and machining costs while maintaining the required structural integrity and dimensional accuracy of the spider carriers through optimized design for the selected manufacturing process
Solution Approach 2:
The patent applies different manufacturing approaches to different regions or features of the spider carrier. Critical load-bearing areas maintain traditional machining for precision, while non-critical areas use cost-reducing methods like casting or forming, thereby optimizing the balance between manufacturing cost and manufacturing precision
2Ease of operation
If multiple separate components are used in the planet carrier assembly, then ease of assembly is improved, but package size and weight increase
Solution Approach 1:
The patent merges multiple separate components of the planet carrier assembly into integrated structures. The spider carriers are designed to combine support functions for multiple planet gears and pinions into single monolithic or near-monolithic structures, reducing the total number of parts, decreasing weight, and minimizing package size while maintaining ease of assembly through modular carrier sets
Solution Approach 2:
The patent implements a nested arrangement where the inner spider carrier and outer spider carrier are positioned concentrically, with the inner carrier nested within the outer carrier structure. This nesting approach minimizes the overall package size and weight by utilizing shared space and common mounting structures, while the modular nature maintains assembly ease
3Strength
If traditional assembly methods are used for planet carriers, then structural integrity is maintained, but package size and weight increase
Solution Approach 1:
The patent transitions from a conventional two-dimensional planar arrangement of planet carriers to a three-dimensional stacked configuration. The inner and outer spider carriers are arranged in axial layers, utilizing the third dimension (axial direction) to organize components. This dimensional change reduces the radial package size and weight while maintaining structural integrity through optimized load paths across the stacked layers
Solution Approach 2:
The patent incorporates preliminary design features into the spider carriers during manufacturing, such as pre-formed attachment points, integrated support structures, and optimized geometry that inherently provide structural integrity. This preliminary action eliminates the need for additional reinforcing elements that would increase volume, while the modular stacked design maintains ease of assembly
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 method reduces construction and machining costs, decreases package size, and minimizes weight while maintaining the structural integrity and functionality of the planetary gear set, enhancing its efficiency and performance.
Implementation Method 1
The spiders may be brazed, welded, staked, pin staked, or rolled to the back plate
Implementation Method 2
The spiders may be brazed, welded, staked, pin staked, or rolled to the back plate
Data Source
AI summary
A method for manufacturing a carrier assembly of a stacked planetary gear set is provided. The method includes forming the inner and outer spiders and attaching the spiders to a back plate or to each other to form the carrier assembly. One or both of the inner and outer carrier spiders are formed from powdered metal, by precision casting, and/or by stamping. The stacked planetary gear set may be axially aligned or axially offset.