Welded Multi-Material Gear Assembly for Low Noise and Weight Reduction
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Solution Overview
Problem
Conventional gear assemblies are heavy and have suboptimal noise, vibration, and harshness (NVH) characteristics due to manufacturing limitations such as heat treatment distortions.
Innovation Solution
A gear assembly comprising a hub, at least one disc, and a ring gear component, where two or more of these components are welded together, utilizing different materials for each component to achieve weight reduction and improved NVH characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional gear assemblies are manufactured using traditional methods (heat treatment, forging), then structural strength is maintained, but weight is excessive and NVH characteristics are suboptimal
Solution Approach 1:
The gear assembly is divided into multiple separate components (hub, discs, ring gear) that are joined together through welding. This segmentation allows each component to be optimized independently for weight while maintaining overall structural integrity through the welded connections.
Solution Approach 2:
The gear assembly uses composite construction with multiple materials - primarily aluminum or aluminum alloys for the hub and discs, and steel for the ring gear. This composite approach enables weight reduction in non-critical components while maintaining strength in load-bearing elements.
2Object-affected harmful factors
If conventional gear assemblies are manufactured using traditional methods, then manufacturing reliability is maintained, but noise, vibration, and harshness characteristics are suboptimal
Solution Approach 1:
The design changes physical parameters of the gear assembly including using thinner disc profiles, optimizing hub geometry, and selecting different materials with different damping characteristics. These parameter changes reduce noise and vibration while the welding process maintains manufacturing reliability.
Solution Approach 2:
Different regions of the gear assembly have different material properties and structural characteristics optimized for their specific functions. The hub and discs use lightweight materials with specific damping properties for vibration reduction, while the ring gear uses stronger material for tooth engagement reliability.
3Weight of moving object
If multiple components are welded together to reduce weight, then weight reduction is achieved (25-46%), but manufacturing complexity increases
Solution Approach 1:
Multiple separate components (hub, one or more discs, ring gear) are merged into a single integrated assembly through welding. This merging achieves weight reduction compared to conventional monolithic designs while the welding process itself simplifies the overall manufacturing by creating a unified structure.
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
The gear assembly achieves a 25% to 46% weight reduction and a 2 dB to 5 dB noise reduction compared to conventional gear assemblies, with improved NVH characteristics and cost savings.
Implementation Method 1
two or more of the hub, the at least one disc, and the ring gear component are welded together
Data Source
AI summary
A lightweight and low noise gear assembly includes a gear assembly that includes a hub, at least one disc, and a ring gear component, wherein two or more of the hub, the at least one disc and the ring gear component are welded together. A lightweight and low noise gear assembly includes a shaft assembly that includes a ring gear, and at least one disc joined with the ring gear. A method of forming a gear assembly, the gear assembly including a hub, at least one disc, and a ring gear component, the method including press-fitting the at least one disc onto the hub and the ring gear, and welding the at least one disc and the ring gear to the hub.