Sun Gear and Planet Carrier Positive-Locking Assembly
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Solution Overview
Problem
Existing methods for joining sun gears and planetary carriers in planetary gears are limited by restricted material choices and unsuitable material pairings, particularly for press fits, which restricts flexibility and increases production costs.
Innovation Solution
A method involving a positive connection between the sun gear and planetary carrier using forming techniques such as rolling, flanging, or roller burnishing to create a secure form-fitting connection, allowing for various material pairings like metal and ceramic or metal and plastic, with optional press fits for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If material-bonding methods (welding, brazing, bonding) are used to join sun gear and planet carrier, then the components can be connected securely, but the choice of materials is limited and many material pairings are unsuitable
Solution Approach 1:
The patent replaces material-bonding methods (welding, brazing, bonding) with a mechanical forming process. A tab on the planet carrier is formed over a groove on the sun gear shaft area, creating a positive mechanical connection. This substitution eliminates material compatibility constraints while maintaining secure connection, enabling diverse material pairings such as metal and ceramic or metal and plastic.
2Reliability
If interference fit is used between sun gear and planet carrier, then the components can be connected, but many material pairings are unsuitable or only conditionally suitable
Solution Approach 1:
The patent replaces the interference fit method with a forming process where a tab is deformed over a groove. This mechanical forming approach creates a positive locking connection that is not constrained by material pairing compatibility, allowing any material combination to be joined securely without the limitations inherent in interference fit methods.
3Ease of manufacture
If separate manufacturing and joining of sun gear and planet carrier is performed, then manufacturing flexibility is maintained, but the joining process is complex and costly
Solution Approach 1:
The groove is pre-formed on the sun gear shaft area during sun gear manufacturing, and the tab is subsequently formed over this groove in a single forming operation. This preliminary preparation of the groove simplifies the joining process compared to traditional methods, reducing complexity and cost while maintaining the benefits of separate component manufacturing.
4Reliability
If traditional joining methods are used, then components can be connected, but production time and cost increase
Solution Approach 1:
The patent replaces multi-step material-bonding or interference fit processes with a single forming operation where the tab is deformed over the groove. This mechanical forming process significantly reduces production time and cost while achieving secure connections capable of transmitting high torques, thereby improving overall productivity.
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 enables simple, inexpensive, and flexible production of sun gear and planetary carrier combinations, allowing for secure connections that can transmit high torques, while enabling the use of diverse materials and improving assembly efficiency.
Implementation Method 1
The component to be deformed, typically the planet carrier, is preferably made of metal. The forming process can be carried out, for example, by rolling, crimping, crimping, embossing, bending, folding or kneading.
Data Source
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AI summary
The present invention relates to a method for manufacturing a system for a planetary gear consisting of a sun gear and a planet carrier, wherein the sun gear and planet carrier are manufactured as separate components and subsequently joined together. According to the invention, the two components are joined together by forming a positive-locking connection between them.