Torque Transmitting Assembly with Raised Portions and Tabs
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Solution Overview
Problem
Current methods for producing pinion carriers and drive shells in vehicle transmissions face issues such as brittle powdered metal parts leading to stress risers and fractures, and stamped parts lacking stiffness, resulting in increased weight, space consumption, and noise due to misalignment under heavy loading.
Innovation Solution
A torque transmitting assembly comprising a cup-shaped drive shell with raised portions and a disk-shaped pinion carrier with axially extending tabs and projections, allowing for improved material distribution and increased strength through welding, reducing weight and production costs by eliminating unnecessary joints and allowing for varied material thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powdered metal parts are used for pinion carrier, then manufacturing flexibility is improved, but structural strength deteriorates due to grain density variation and stress risers
Solution Approach 1:
The patent applies local quality by varying the material thickness in different regions of the pinion carrier. The carrier has different thickness zones: thicker sections at critical stress points (such as where retaining faces meet the carrier body) and thinner sections in non-critical areas. This allows the component to have sufficient strength where needed while minimizing overall weight and material usage.
2Strength
If material thickness is increased to counteract stress risers in powdered metal parts, then structural strength is improved, but weight and space consumption increase
Solution Approach 1:
The patent applies local quality by varying the material thickness in different regions of the pinion carrier. The carrier has different thickness zones: thicker sections at critical stress points (such as where retaining faces meet the carrier body) and thinner sections in non-critical areas. This allows the component to have sufficient strength where needed while minimizing overall weight and material usage.
3Volume of moving object
If stamped parts are used for pinion carrier, then space consumption is reduced, but stiffness deteriorates causing deflection and misalignment
Solution Approach 1:
The patent applies local quality by varying the material thickness in different regions of the pinion carrier. The carrier has different thickness zones: thicker sections at critical stress points (such as where retaining faces meet the carrier body) and thinner sections in non-critical areas. This allows the component to have sufficient strength where needed while minimizing overall weight and material usage.
4Weight of moving object
If cold forming is used to create varied material thickness, then weight is minimized and stiffness is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the pinion carrier and drive shell into a single integrated component produced through cold forming. This consolidation eliminates the need for separate manufacturing processes and assembly operations for multiple parts, reducing overall manufacturing complexity while maintaining the benefits of varied material thickness and improved stiffness.
Data Source
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AI summary
A torque transmitting assembly is provided. The torque transmitting assembly includes a generally cup shaped outer shell having a closed end and an open end. The closed end has at least one raised portion formed therein. The outer shell includes an outwardly extending lip surrounding the open end of the outer shell. The open end of the outer shell is adapted to be operatively engaged with a first rotating member. A generally disk shaped inner member has a central aperture and a central axis. The inner member includes at least one tab extending axially outwardly therefrom and engages the raised portion of the outer shell to facilitate a transfer of rotation between the outer shell and the inner member. The central aperture is adapted to be operatively engaged with a second rotating member. The inner member is received inside said outer shell.