Sun Gear and Planet Carrier Form-Fit Assembly for Material Flexibility
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Solution Overview
Problem
Existing methods for manufacturing sun gears and planet carriers in planetary gear units are limited by material compatibility and the cost-effectiveness of joining methods, which restrict the choice of materials and flexibility in component pairing.
Innovation Solution
A method that establishes a form-fit connection between the sun gear and planet carrier through deformation, allowing for the use of different materials like metal, ceramics, or plastic, and optionally a press-fit connection, using techniques such as roller burnishing, crimping, or embossing to create a reliable and cost-effective assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If joining methods establishing a material bond (welding, soldering, adhesive bonding) are used, then a strong connection is achieved, but the choice of materials is limited
Solution Approach 1:
The patent replaces material bond joining methods (welding, soldering, adhesive bonding) with a mechanical form-fit connection. The planet carrier features a projection that is deformed into a recess of the sun gear, creating a mechanical interlock that does not depend on material compatibility for bonding. This substitution allows any material combination while maintaining connection strength through geometric interlocking rather than material bonding.
Solution Approach 2:
The patent changes the joining mechanism from chemical/material-based bonding to physical/geometric form-fit connection. By deforming the projection into the recess, the connection relies on geometric parameters (shape, size, interference fit) rather than material properties, thereby enabling versatile material selection including metal-ceramic and metal-plastic combinations while preserving connection integrity.
2Adaptability or versatility
If interference fit is used between sun gear and planet carrier, then material compatibility is improved, but many material pairs are not suitable for interference fit
Solution Approach 1:
The patent segments the connection into two functional parts: a form-fit geometric interlock (projection into recess) and an optional force-fit press-fit connection. This segmentation allows the form-fit portion to handle material compatibility while the press-fit portion provides additional mechanical engagement. The divided approach enables versatile material pairing without compromising manufacturability, as each segment can be optimized independently.
Solution Approach 2:
The patent incorporates a lug and recess geometry design that prepares the components for easy assembly. The pre-formed lug on the planet carrier and matching recess on the sun gear enable straightforward deformation and interlocking during assembly, making the manufacturing process simple despite the versatile material options. The preliminary geometric design facilitates ease of manufacture across different material pairs.
3Adaptability or versatility
If separate manufacturing of sun gear and planet carrier followed by joining is used, then component optimization is achieved, but production complexity increases
Solution Approach 1:
The patent merges the joining operation with the manufacturing process by deforming the projection directly during or after component fabrication. The form-fit connection is created through a single deformation step that interlocks the pre-optimized components, eliminating the need for separate, complex joining procedures. This merging reduces production complexity while preserving the benefits of separate component optimization.
Solution Approach 2:
The deformation process creates the form-fit connection using the material's own plasticity and elasticity. The projection is deformed into the recess through self-contained mechanical action, requiring no external bonding agents, welding equipment, or complex assembly machinery. This self-service approach simplifies the production process while maintaining component optimization benefits.
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 approach enables a flexible and cost-effective production of composite components with enhanced material selection and connection reliability, supporting high-torque transmission and simplifying the manufacturing process.
Implementation Method 1
the lug of the planet carrier is, by means of deforming, at least partially deformed into the groove of the sun gear
Implementation Method 2
Deforming may be executed e.g. by means of roller burnishing
Implementation Method 3
a force-fit connection, in addition to the form-fit connection, can be established between the two components, preferably in the form of a press-fit connection
Data Source
AI summary
A method of manufacturing a composite including a sun gear and a planet carrier for a planetary gear unit, the sun gear and the planet carrier being manufactured as separate components and then joined together. The two components are joined together by establishing, by deformation, a form-fit connection between the two components.