JP4103839B2 - Carrier plate and manufacturing method thereof - Google Patents

Description

  The present invention relates to a carrier plate and a manufacturing method thereof, and more particularly to a carrier plate of a carrier that rotatably supports a rotating body such as a gear and a pulley, and a manufacturing method thereof.

  In general, an automatic transmission of an automobile is provided with a planetary gear device, and the planetary gear device includes a ring gear, a sun gear, a pinion that meshes with the ring gear and the sun gear, and a carrier that supports the pinion.

  FIG. 9 shows an example of the carrier plate of such a planetary gear device (see Patent Document 1). The carrier plate 101 includes a hollow disc-shaped carrier main body 102 that supports a support shaft of the pinion gear, and a plurality of tongue-like leg portions 103 that extend in the axial direction from the outer peripheral end of the carrier main body 102.

  The carrier plate 101 is formed by punching a carrier material 104 (also referred to as a blank) having a tongue-like leg portion from a disc-like punching material punched by a press, and thereafter the leg portion 103 of the carrier material 104 is axially moved. It is formed by bending it. As shown in FIG. 9B, the carrier material 104 has a plurality of tongue-shaped leg portions 103 radially arranged at equal intervals on the outer periphery of a hollow disc-shaped carrier body 102 formed by punching.

Also, there is a carrier structure of a planetary gear device, in which the shape of the leg portion is formed into a V-shape, M-shape, L-shape, U-shape, etc., thereby improving durability and reducing gear noise. It is disclosed (see Patent Document 2).
Japanese Patent Laid-Open No. 7-136721 JP 7-332475 A

  However, in the former, since the leg portion continuous to the plate portion of the carrier plate is simply bent in the axial direction, the thickness of the leg portion is the same as the thickness of the plate portion, so that the rigidity is low. It has become. If the rigidity of the leg portion is low, the leg portion cannot endure the torsional deformation of the carrier, causing meshing misalignment, which may cause problems such as deterioration in durability and increase in gear noise.

  In the latter case, the yield of the material steel plate is lower than that of the conventional structure, and the manufacturing process is complicated, resulting in an increase in manufacturing cost.

  The present invention has been made to solve the above-described problems, and provides a highly rigid carrier plate having a sufficient coupling length of the legs for coupling the carrier plate and the flange, and a method for manufacturing the same. The task is to do.

  The carrier plate of the present invention is a carrier plate that integrally includes a plate portion that supports a gear and a plurality of leg portions extending in the axial direction of the plate portion, and the leg portion includes a plurality of wall portions. It is characterized by having.

  In a preferred aspect of the present invention, it is preferable that the wall portion is an outer wall projecting at an outer edge portion of the plate portion and an inner wall projecting at an inner edge portion of the plate portion.

  In a preferred embodiment of the present invention, the wall portion is preferably an outer wall protruding from an outer edge portion of the plate portion, and a side wall extending continuously in the radial direction of the plate portion. Here, it is preferable that the wall portion further has an inner wall projecting to an inner edge portion of the plate portion.

  The carrier plate of the present invention is a carrier plate that integrally includes a plate portion that supports a gear and a plurality of leg portions that extend in the axial direction of the plate portion, and the leg portions are continuous with the plate portion. A plurality of wall portions and a bottom portion parallel to the plate portion continuous to the wall portions.

  In a preferred embodiment of the present invention, the wall portion is preferably a side wall protruding in the radial direction of the plate portion. Here, it is preferable that the wall portion further has an inner wall projecting at an inner edge portion of the plate portion, and the wall portion may further have an outer wall projecting at an outer edge portion of the plate portion.

  The carrier plate of the present invention is a carrier plate that integrally includes a plate portion that supports a gear and a plurality of leg portions that extend in the axial direction of the plate portion, and the leg portion is an outer edge of the plate portion. It is a laminated body in which a tongue portion that is radially formed continuously is bent in close contact with the portion.

  The carrier plate manufacturing method of the present invention is a method of manufacturing a carrier plate that integrally includes a plate portion that supports a gear and a plurality of legs that extend in the axial direction of the plate portion. A blank punching step for forming the plate portion and a blank having a plurality of tongue portions radially extending from the plate portion to an outer peripheral side and / or an inner peripheral side; and the leg portion by bending the tongue portion in an axial direction And a folding step of forming the structure.

  The carrier plate manufacturing method of the present invention is a method of manufacturing a carrier plate that integrally includes a plate portion that supports a gear and a plurality of legs that extend in the axial direction of the plate portion. It has a blank punching process for punching a blank having a predetermined shape, and a plurality of draw forming processes for forming a bottomed leg portion.

  The carrier plate manufacturing method of the present invention is a method of manufacturing a carrier plate that integrally includes a plate portion that supports a gear and a plurality of legs that extend in the axial direction of the plate portion. A blank punching step for forming a blank having a plurality of tongue portions extending radially from the plate portion to the outer peripheral side from the plate portion; and an uneven wave perpendicular to the longitudinal direction of the tongue portion on the tongue portion Forming a corrugation step, a bending step of bending the corrugated tongue portion in an axial direction of the plate portion, and the corrugated tongue portion by compressing the bent tongue portion along the axial direction. And a close-contact bending step of folding the screen into a folding screen.

  The carrier plate manufacturing method of the present invention is a method of manufacturing a carrier plate that integrally includes a plate portion that supports a gear and a plurality of legs that extend in the axial direction of the plate portion. A blank punching process for forming a blank having the plate portion and a plurality of tongue portions extending radially outward from the plate portion, and bending the tongue portion in a concave shape along the longitudinal direction of the tongue portion It comprises a preliminary bending step, a thickening step of increasing the thickness of the pre-bent tongue, and a bending step of bending the increased thickness of the tongue in the axial direction of the plate portion.

  In the carrier plate according to the present invention, the leg portion of any carrier plate is thicker than the thickness of the plate portion or is composed of a plurality of wall portions. Compared to a conventional leg portion made of a single plate, it has high rigidity. Therefore, the legs cannot endure the torsional deformation of the carrier, causing a meshing shift of the gears, and problems such as deterioration in durability and increase in gear noise do not occur.

  Moreover, since it can press-form using a steel plate as a raw material, manufacturing cost can be suppressed.

  The carrier includes a carrier plate having a plurality of legs formed integrally with the plate portion, and a flange coupled to the tips of the plurality of legs so as to face the plate portion.

  The flange has a fitting hole corresponding to the shape of the tip of the leg, and the structure is integrated with the carrier plate by fitting the tip of the leg into this fitting hole and welding or brazing the periphery. . Therefore, the longer the welding or brazing length, the higher the rigidity as the carrier. The present invention has been made from such a viewpoint.

  Hereinafter, the present invention will be described in detail by way of examples. In the examples, a carrier plate having three legs and a manufacturing method thereof were used, and the material material used was SAPH440 having a thickness of 4.5 mm.

The carrier plate according to the first embodiment is a carrier plate that integrally includes a plate portion that supports a gear and a plurality of leg portions that extend in the axial direction of the plate portion, and the leg portions include a plurality of wall portions. A carrier plate characterized by having
It is a carrier plate in which the wall portion is composed of an outer wall protruding from the outer edge portion of the plate portion and an inner wall protruding from the inner edge portion of the plate portion.

  FIG. 1A shows a carrier plate 10 having wall portions on the inner and outer peripheral edges of the plate portion. The leg part 12 enclosed with a broken line is comprised from the outer wall 12o and the inner wall 12i which followed the plate part 14. FIG.

  The carrier plate 10 having such legs 12 is manufactured as follows. First, a blank B having tongue portions 12o 'and 12i' is radially punched from a material steel plate as shown in FIG. Next, the outer wall 12o, the inner wall 12i, and the shaft hole 16 can be formed by bending the tongue portions 12o 'and 12i' along the axial direction.

  The leg portion of the carrier plate 10 according to the present embodiment has an outer wall 12o and an inner wall 12i having the same thickness as that of the plate portion 14 in one leg portion 12, so that the rigidity is 1.5 times that of the conventional leg portion. Can have.

  The carrier plate of the second embodiment is a carrier plate having a plurality of wall portions as in the first embodiment. The outer wall protrudes from the outer edge of the plate portion, and the plate portion continues to the outer wall. It is a carrier plate comprised with the side wall extended in the radial direction.

  The carrier plate 20 of the present embodiment includes an outer wall 12o extending in the axial direction from the outer edge portion of the plate portion 14 shown in FIG. 2A and a side wall 12s extending in a radial direction continuously to the outer wall 12o. It has the leg part 12 comprised.

  A carrier plate having such a leg 12 is manufactured as follows.

  First, a blank B having a T-shaped tongue 12 'as shown in FIG. Next, the U-shaped portions 12s ′ at both ends of the T-shaped tongue portion 12 ′ are bent so as to have a desired angle α along the broken line L (for example, after the tongue portion 12 ′ is bent in the axial direction, 12s ′ is the side wall portion 12s in the radial direction of the plate portion 14). Next, the tongue portion 12o ′ having the tongue portions 12s ′ on both sides along the outer edge of the plate portion 14 is bent along the axial direction to thereby have the leg portion 12 composed of the outer wall portion 12o and the side wall portion 12s. The carrier plate 20 can be obtained.

  The carrier plate of Example 3 is the carrier plate of Example 2, and has an inner wall whose wall part further protrudes to the inner edge part of the plate part.

  The carrier plate 30 of the present embodiment includes an outer wall 12o extending in the axial direction from the outer edge portion of the plate portion 14 shown in FIG. 3A, and a side wall 12s extending continuously in the radial direction from the outer wall 12o. The leg part 12 is comprised from the inner wall 12i extended from the inner periphery of the plate part 14 to an axial direction.

  A carrier plate having such a leg 12 is manufactured as follows.

  First, a blank B having a T-shaped tongue portion 12 'and a U-shaped tongue portion 12i' as shown in FIG. Next, the U-shaped portions 12s ′ at both ends of the T-shaped tongue portion 12 ′ are bent so as to have a desired angle α along the broken line L (for example, after the tongue portion 12 ′ is bent in the axial direction, 12s ′ is the side wall portion 12s in the radial direction of the plate portion 14). Next, a tongue portion 12o ′ having tongue portions 12s ′ on both sides along the outer edge of the plate portion 14 is bent along the axial direction, and at the same time, 12i ′ is bent along the inner peripheral edge in the axial direction, thereby forming the outer wall 12o. The side wall portion 12s, the inner wall portion 12i, and the shaft hole 16 are formed.

  The leg portion 12 of the carrier plate 30 of this embodiment has a cross section in which one leg portion 12 is surrounded by an outer wall 12o having the same thickness as the plate portion 14, a side wall 12s extending in the radial direction, and an inner wall 12i. The shape is a substantially square shape. Such a leg portion having a substantially rectangular shape in cross section has higher rigidity.

  In the carrier plates 10 to 30 described above, the tongue portion 12 ′ formed in the blank B is bent in the axial direction to form the leg portion 12 composed of a plurality of wall portions. Are formed by drawing. That is, a carrier plate that integrally includes a plate portion that supports the gear and a plurality of leg portions that extend in the axial direction of the plate portion, and the leg portions include a plurality of wall portions that are continuous with the plate portion, The carrier plate has a bottom portion parallel to the plate portion that is continuous with the wall portion, and the wall portion is constituted by a side wall projecting in the radial direction of the plate portion.

  As shown in the perspective view of FIG. 4A, the carrier plate 40 of the present embodiment is a leg composed of a wall portion 12s protruding from the plate surface 14 and a bottom portion 12u of the leg portion 12 parallel to the plate surface 14. Part 12 is provided.

The carrier plate 40 having such legs 12 is formed as follows.
First, a blank having the shape of FIG. 4D is punched from the material steel plate. Next, the leg portion 12 is drawn through 8 to 10 steps. After drawing, the shaft hole 16 is punched to form a pinion gear support hole to obtain a desired carrier plate 40. FIG. 4B shows a BB cross section parallel to the plate surface 14 of FIG. The leg portion 12 includes a wall portion 12s protruding continuously from the plate portion 14 and a bottom portion 12u parallel to the plate portion 14 continuing to the wall portion 12s.

  In the fifth embodiment, similarly to the fourth embodiment, the leg portion is formed by drawing. The carrier plate of the fourth embodiment further includes an inner wall protruding from the inner edge of the plate portion. As shown in the perspective view of FIG. 5A, the carrier plate 50 of the present embodiment has a leg portion 12 having a bottom 12u integrally including a side wall 12s protruding from the plate surface 14 and an inner wall 12i. Yes.

  The carrier plate 50 having such legs 12 is formed as follows. First, a blank having the shape shown in FIG. Next, the leg portion 12 is drawn through 8 to 10 steps. After drawing, the shaft hole 16 is punched to form a support hole for the pinion gear, and a desired carrier plate 50 is obtained. FIG.5 (b) shows the BB cross section parallel to the plate surface 14 of (c) which is an AA cross section. The leg portion 12 surrounded by a broken line is composed of a side wall portion 12s protruding continuously from the plate portion 14, an inner wall portion 12i continuous to the side wall portion 12s, and a bottom portion 12u parallel to the plate portion 14.

  In the sixth embodiment, the leg portions are drawn as in the fifth embodiment, and the carrier plate of the fifth embodiment is further provided with an outer wall protruding from the outer edge portion of the plate portion. As shown in the perspective view of FIG. 6A, the carrier plate 60 of the present embodiment has legs 12u having bottoms 12u integrally including an outer wall 12o, a side wall 12s, and an inner wall 12i protruding from the outer peripheral edge of the plate surface 14. Part 12 is provided.

  The carrier plate 60 having such legs 12 is formed as follows. First, a blank having the shape shown in FIG. Next, the leg portion 12 is drawn through 8 to 10 steps. After drawing, the shaft hole 16 is punched to form a pinion gear support hole to obtain a desired carrier plate 60. 6B shows a BB cross section parallel to the plate surface 14 of FIG. 6C, which is an AA cross section. The leg portion 12 surrounded by a broken line includes a protruding outer wall 12o, a side wall 12s and an inner wall 12i formed continuously from the plate portion 14 and a bottom portion 12u parallel to the plate portion 14.

  The leg portion of the carrier plate 60 of this embodiment has a very high rigidity because it has a cylindrical shape with a bottom, that is, a square shape in which the cross section is integrally formed.

  The carrier plate according to the seventh embodiment is a carrier plate that integrally includes a plate portion that supports a gear and a plurality of leg portions that extend in the axial direction of the plate portion, and the leg portion is an outer edge portion of the plate portion. A carrier plate, characterized in that it is a laminate in which tongue portions that are continuously formed in a radial pattern are closely attached and bent.

  As shown in the sectional view of FIG. 7A, the carrier plate 70 of the present embodiment is formed by folding the leg portions with a predetermined length and folding them. The manufacturing method is shown in (b1) to (b5) of FIG.

  First, in the punching step (b1), the blank B having the plate portion 14 and the three tongue portions 12 'radially from the center of the plate portion 14 is punched from the material steel plate. Next, in a wave forming step (b2), a predetermined number of waves (uneven curved surfaces) 21 are formed at right angles to the radial direction of the tongue 12 '. At this time, the wave height h is preferably about 2 to 3 times the plate thickness t. Further, the number of waves (1/2 of the number of turns) varies depending on the thickness t, but is preferably about 3 to 5. Next, the tongue 12 'is bent along the axis L in the bending step (b3). It is preferable to provide a recess 23 so that a folding screen-like close contact bending can be easily performed on the valley portion 22 of the tongue portion 12 ′ that is corrugated simultaneously with the bending (see a partially enlarged view of FIG. 7B 3). The curvature of the recess 23 is not particularly limited, but is preferably about 0.3 to 0.6 t. In the close contact bending process of (b4), the corrugated tongue 12 'bent along the axis L is vertically compressed and folded into a folding screen to form the stacked legs 12. The leg 12 does not cause inconveniences such as cracking even if it is tightly bent by the concave portion 23 of the valley portion 22 formed in the bending process. After forming the leg portion 12, the desired carrier plate 70 can be formed by punching the shaft hole 16 in the center of the plate portion 14 in the drilling step (b5). The carrier plate 70 formed in this way can have high rigidity because the cross section of the leg portion parallel to the plate portion 14 can be made extremely thicker than the plate thickness of the plate portion.

  In Example 7, the tongue portion 12 ′ was folded in a folding screen and laminated to increase the rigidity. In this embodiment, the tongue portion 12 ′ is bent 180 ° outward, that is, the leg portion 12 is doubled, and the tip end of the tongue portion 12 ′ is welded to the plate portion 14. A cross section of the carrier plate 80 of this embodiment is shown in FIG. The thickness of the leg portion 12 can be doubled by the thickness of the plate portion 14 by folding and welding, so that the rigidity of the leg portion 12 is also doubled compared to the case where the single plate is simply bent. Can do.

  The carrier plate of Example 9 is a carrier plate in which the plate thickness of the leg portion is thicker than the plate thickness of the plate portion. FIG. 9A is a schematic front view of the carrier plate 90, and the AA cross section is shown below the front view. The carrier plate 90 is obtained by integrally forming a plate portion 14 having a shaft hole 16 through which a rotation shaft is inserted at the center and three leg portions 12 extending in the direction of the axis L by press molding. Here, the thickness t1 of the leg portion 12 is formed to be thicker than the plate thickness t0 of the plate portion 14, and has a shape having excellent rigidity.

  FIG. 9B is a schematic diagram for explaining a method for manufacturing the carrier plate 90.

  First, a blank B having a plate portion 14 and three tongue portions 12 'extending radially from the plate portion 14 is punched from the material steel plate in a punching step (b1).

  Next, in the pre-bending step (b2), the center portion in the width direction of the tongue portion 12 'is bent and formed into an arc shape in a cross section (12a) so as to protrude from the bottom surface 14' of the plate portion 14. This is to increase the thickness effectively in the next step. Subsequently, in the thickening step (b3), the pre-bent tongue 12 'is further thickened by a known upsetting method. In this way, the thickness t1 of the leg portion 12 can be made twice or more the thickness t0 of the plate portion by increasing the thickness of the tongue portion 12 'in the unfolded state. In the thickening step (b3), it is desirable to form the convex portion 18 in the vicinity of the bent portion of the thickened tongue portion 12 'as shown in the lower sectional view. Since the thickened tongue portion 12 ′ has a large plate thickness and is work-hardened, if it is bent in the direction of the axis L to form the leg portion 12, a crack may occur in the bent portion. For this reason, in the next bending process (b4), it is desirable to bend and crush the convex part 18 formed at the thickening process (b3). By forming the leg portion 12 by bending the convex portion 18 while crushing, it is possible to prevent the occurrence of cracks during bending.

  Next, a desired carrier plate 90 can be obtained by punching the shaft hole 16 through which the rotation shaft is inserted into the central portion of the plate portion 14 in the punching step (b5).

  The embodiment described above has higher rigidity than a carrier plate formed by press forming according to the prior art. Moreover, since it can form by the simple method called press molding, compared with other shaping | molding methods, such as forging, sintering, and casting, manufacturing cost can be reduced significantly.

  In addition, this invention is not limited to the above Example, It can change in the range of the main point of this invention. For example, the tongue portion is folded in Example 8 to form a leg portion having a double thickness, but may be folded twice or more. Moreover, although it turned back to the outer side of the plate part, it can also be turned inside instead of the outside.

  Since the carrier plate of the present invention can be formed by a very simple method called press molding, it can be suitably used for the production of planetary carriers for planetary gear devices such as continuously variable transmissions and automatic transmissions for automobiles.

It is explanatory drawing explaining the carrier plate 10 of Example 1. FIG. (A) X-plane schematic diagram of the carrier plate 10, (b) AA cross-sectional schematic diagram of (a), (c) Blank shape It is explanatory drawing explaining the carrier plate 20 of Example 2. FIG. (A) X-plane schematic diagram of the carrier plate 20, (b) AA cross-sectional schematic diagram of (a), (c) Blank shape It is explanatory drawing explaining the carrier plate 30 of Example 3. FIG. (A) X-plane schematic diagram of the carrier plate 30, (b) AA cross-sectional schematic diagram of (a), (c) Blank shape It is explanatory drawing explaining the carrier plate 40 of Example 4. FIG. (A) Carrier plate 40 perspective view, (b) BB cross-sectional front schematic diagram of (c), (c) (A) cross-sectional schematic diagram of (b), (d) Blank shape It is explanatory drawing explaining the carrier plate 50 of Example 5. FIG. (A) Carrier plate 50 perspective view, (b) BB cross-sectional front schematic diagram of (c), (c) (A) cross-sectional schematic diagram of (b), (d) Blank shape It is explanatory drawing explaining the carrier plate 60 of Example 6. FIG. (A) Carrier plate 60 perspective view, (b) BB cross-sectional front schematic diagram of (c), (c) (A) cross-sectional schematic diagram of (b), (d) Blank shape It is explanatory drawing explaining the carrier plate 70 of Example 7, and its manufacturing method. (A) Plane schematic diagram of carrier plate 70, (b) Manufacturing process schematic diagram, (b1) Punching process, (b2) Wave forming process, (b3) Leg bending process, (b4) Crushing (leg forming) process (B5) Drilling process 9 is a schematic cross-sectional view showing a carrier plate 80 of Example 8. FIG. It is explanatory drawing explaining the carrier plate 90 of Example 9, and its manufacturing method. (A) Plane schematic diagram of carrier plate 90, (b) Manufacturing process schematic diagram, (b1) Punching process, (b2) Pre-bending process, (b3) Thickening process, (b4) Leg bending process, (b5) Drilling process It is explanatory drawing explaining the carrier plate 101 of a prior art example. (A) Perspective view of carrier plate 101, (b) Blank shape

Explanation of symbols

12: Leg part 12i: Inner wall part 12o: Outer wall part 12s: Side wall part 12u: Bottom part 12 ': Tongue part 14: Plate part 16: Shaft hole B: Blank L: Axis line

Claims (2)

A carrier plate integrally having a plate portion supporting a gear and a plurality of legs extending in the axial direction of the plate portion;
The carrier plate according to claim 1, wherein the leg portion is a laminated body in which a tongue portion that is radially formed continuously from the outer edge portion of the plate portion is closely attached and bent. A carrier plate manufacturing method integrally having a plate portion supporting a gear and a plurality of legs extending in the axial direction of the plate portion,
A blank punching process for forming a blank having a plurality of tongues extending radially from the plate part to the outer peripheral side from the plate material,
Forming a corrugated wave perpendicular to the longitudinal direction of the tongue on the tongue;
A bending step of bending the corrugated tongue portion in the axial direction of the plate portion;
A method of manufacturing a carrier plate, comprising: a contact bending step of folding the corrugated tongue in a folding screen by compressing the bent tongue along the axial direction.

Images