US20010018381A1 - Carrier and method of manufacturing carrier - Google Patents

Carrier and method of manufacturing carrier Download PDF

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Publication number
US20010018381A1
US20010018381A1 US09/783,992 US78399201A US2001018381A1 US 20010018381 A1 US20010018381 A1 US 20010018381A1 US 78399201 A US78399201 A US 78399201A US 2001018381 A1 US2001018381 A1 US 2001018381A1
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US
United States
Prior art keywords
flanges
joints
carrier
closed
openings
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
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US09/783,992
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English (en)
Inventor
Takashi Suzumura
Keiichi Matsunaga
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyota Motor Corp
MEG Inc
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Assigned to MEG INC., TOYOTA JIDOSHA KABUSHIKI KAISHA reassignment MEG INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MATSUNAGA, KEIICHI, SUZUMURA, TAKASHI
Publication of US20010018381A1 publication Critical patent/US20010018381A1/en
Priority to US10/689,613 priority Critical patent/US7100416B2/en
Abandoned legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H1/00—Toothed gearings for conveying rotary motion
    • F16H1/28—Toothed gearings for conveying rotary motion with gears having orbital motion
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H57/00—General details of gearing
    • F16H57/08—General details of gearing of gearings with members having orbital motion
    • F16H57/082—Planet carriers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49481—Wheel making
    • Y10T29/49492—Land wheel
    • Y10T29/49533—Hub making
    • Y10T29/49536—Hub shaping

Definitions

  • the invention relates to a carrier and a method of manufacturing the carrier and, more particularly, to a carrier for rotatably supporting rotating bodies such as gears and pulleys and a method of manufacturing the carrier.
  • a planetary gear unit is generally employed in an automatic transmission of an automobile.
  • the planetary gear unit has a sun gear, a ring gear disposed around the sun gear, a planetary gear or a pinion (hereinafter referred to generically as a planetary gear) disposed between the sun gear and the ring gear so as to engage them, and a carrier for rotatably supporting the planetary gear.
  • Japanese Patent Application Laid-Open No. HEI 10-288248 discloses a planetary gear unit for an automatic transmission according to the related art of the invention.
  • This planetary gear unit has a ring gear, a sun gear and a pinion that engage one another, and a carrier for rotatably supporting the pinion.
  • the carrier is composed of a boss connected to a shaft of the automatic transmission, a radially extended plate, a carrier plate formed of a salient axially protruding from the radially extended plate, and a base plate having holes into which the salient of the carrier plate is fitted.
  • the salient of the carrier plate is made thicker than the boss and the radially extended plate by differential-thickness press working.
  • a carrier C′ is composed of a carrier plate 31 spline-connected to a shaft of an automatic transmission and a disc-shaped base plate 32 .
  • the carrier plate 31 is composed of a disc-shaped plate 31 a and a plurality of columns (salients) 33 protruding towards the base plate 32 from the outer periphery of the plate 31 a in a direction substantially parallel to the shaft. Fitting portions 33 a with a reduced thickness are formed at the ends of the columns 33 .
  • the base plate 32 is constructed of an annular sheet material having at its center a through-hole 32 a through which a shaft (not shown) or a sun gear (not shown) is inserted.
  • Fitting holes 32 b into which the fitting portions 33 a formed at the ends of the columns 33 of the carrier plate 31 are fitted, are formed on the outer circumferential side of the base plate 32 .
  • the carrier plate 31 and the base plate 32 are connected by fitting the fitting portions 33 a formed at the ends of the columns 33 into the fitting holes 32 b and welding parts of the fitting portions 33 a fitted into the fitting holes 32 b to the base plate 32 . That is, according to this carrier, the carrier plate 31 and the base plate 32 are formed individually, assembled, welded, and then integrated.
  • the carrier plate 31 and the base plate 32 are obtained from press-worked sheet materials.
  • the aforementioned publication also discloses that the carrier plate and the base plate can be formed by forging or forging+cutting and the like instead of press working.
  • the pinion is inserted into the carrier among the columns 33 and between the carrier plate 31 and the base plate 32 , and openings 35 defining a space for engagement of tooth tops of the pinion gear with the ring gear are made.
  • the base plate 32 and the carrier plate 31 having the columns 33 as in the carrier of the aforementioned related art are formed by sintering, assembled, connected by waxing instead of welding, and then integrated into a carrier.
  • the carrier plate 31 , the base plate 32 and the columns 33 are cast and integrated into a carrier.
  • the carrier plate 31 and the base plate 32 are cut after the carrier has been formed integrally.
  • the carrier is required to guarantee a high degree of parallel precision of the opposed faces of the carrier plate 31 and the base plate 32 .
  • the parallel precision of the opposed faces cannot be enhanced due to an error caused during an assembling operation, a tolerance of pressing during the manufacture of the carrier plate 31 and the base plate 32 , a distortion caused during sintering, welding heat at the time of connection, or a distortion caused by waxing.
  • the carrier into which the carrier plate, the base plate and the joints are cast and integrated it is necessary to cut the carrier plate and the base plate after the carrier has been formed integrally. For this reason, the number of manufacturing processes increases and materials are wasted, which causes a problem of an increase of the cost. Because the carrier that has been formed by casting is obtained simply by forming a molten material and a density of contents of the carrier is low and there is no material flow, there is caused a problem of even lower rigidity.
  • the carrier that has been manufactured by sintering or forging needs to be made thick so as to guarantee predetermined rigidity. This causes problems of more wasted materials and the inability to save the weight of the carrier.
  • the invention has been made in consideration of the aforementioned problems. It is an object of the invention to provide a carrier having a construction capable of enhancing parallel precision of opposed faces with a reduced number of processes and saving the weight through increased rigidity. It is also an object of the invention to provide a carrier having a construction that makes its manufacture easy.
  • a carrier according to a first aspect of the invention wherein a pair of flanges opposed to each other and designed to rotatably support rotating bodies therebetween and joints for connecting the flanges are integrally formed through plastic deformation of a single material.
  • the flanges and the joints are integrally formed through plastic deformation of a single material with uninterrupted flow of the material. Therefore, the number of parts is reduced and the processes of assembling and bonding become unnecessary so that the carrier is formed with a reduced number of processes. Thus, the parallel precision of the opposed faces is enhanced at a low cost, and the weight can be saved through high rigidity.
  • the joints may be disposed along outer peripheries of the flanges.
  • a carrier suited to support, as rotating bodies that are rotatably supported, planetary gears engaging sun gears in an automatic transmission.
  • a plurality of joints are disposed along the circumference of the flanges discontinuously, and openings are made among the joints. Holes through which shafts for supporting the sun gears are inserted are formed at the centers of the flanges.
  • a groove may be formed on a border between the flanges and the joints.
  • the groove is formed on the border between the flanges and the joints especially on the side of the inner surface of the carrier, the process of bending is guided by the groove and the border between the flanges and the joints is formed with high precision. Therefore, an integral-type carrier having a construction that makes its manufacture easy is provided.
  • a material is formed into the shape of a cup having an opening, and the opening of the cup is closed off so that a pair of flanges opposed to each other and designed to rotatably support rotating bodies therebetween and joints for connecting the flanges are integrally formed.
  • the material is closed off so that the end faces of the opening in the cup are shrunk radially inwardly.
  • a carrier having a pair of flanges opposed to each other and designed to rotatably support rotating bodies therebetween and joints for connecting the flanges.
  • the flanges and the joints are integrally formed from a single material with uninterrupted flow of the material, the number of parts is reduced and the processes of assembling and bonding become unnecessary so that the carrier is formed with a reduced number of processes.
  • a method of manufacturing a carrier wherein the parallel precision of opposed faces can be enhanced at a low cost and wherein the weight can be saved through high rigidity.
  • a bottom of the material formed into the shape of the cup is turned into one of the flanges.
  • Peripheral walls adjacent to the bottom are turned into the joints.
  • An opening-side portion of the cup-shaped material, which is to be closed off, is turned into the other flange.
  • the material is selected from a plate material, a rod material and a tubular material.
  • a method of manufacturing a carrier easily is provided in a more concrete form.
  • the material can be formed into the shape of a cup by being bent and/or drawn.
  • the material can be formed into the shape of a cup by shrinking one end of the material.
  • the material can be formed into the shape of a cup by being extruded.
  • both end openings of a tubular material are closed off, whereby a pair of flanges opposed to each other and designed to rotatably support rotating bodies therebetween and joints for connecting the flanges are formed integrally.
  • both end faces of openings of a tubular material are simultaneously closed off so that they are shrunk radially inwardly.
  • a carrier having a pair of flanges opposed to each other and designed to rotatably support rotating bodies therebetween and joints for connecting the flanges is manufactured easily.
  • the flanges and the joints are integrally formed from a single material with uninterrupted flow of the material, the number of parts is reduced and the processes of assembling and bonding become unnecessary so that the carrier can be formed with a reduced number of processes.
  • a method of manufacturing a carrier wherein the parallel precision of opposed faces can be enhanced at a low cost and wherein the weight can be saved through high rigidity.
  • Axial centers of a side wall of the tubular material are turned into the joints of the carrier, and both axial ends of the side wall of the tubular material, which are to be closed off, are turned into a pair of flanges.
  • a carrier having a configuration wherein joints are integrated with the outer peripheries of flanges is manufactured.
  • a bending guide such as a groove may be formed on a border between pre-joints and the other pre-flange before the material is closed off.
  • the process of bending is guided by the guide precisely when the material is closed off. Therefore, the parallel precision and the dimensional precision of the opposed faces of the flanges are further enhanced.
  • Openings may be made in pre-joints of the material before the material is closed off.
  • the openings are made, the outer peripheral faces of the flanges are curved towards the inside of the openings when the material is closed off. That is, the openings are made in the joints without affecting the parallel precision of the opposed faces of the flanges. Therefore the parallel precision of the opposed faces is further enhanced.
  • the openings are made by forming the contour of the material and trimming it at the same time. Thus, the number of processes can be further reduced.
  • mandrels may be inserted from the openings made in the pre-joints of the material so as to close off the material.
  • the material is closed off with the mandrels inserted into the pre-joints of the material from the openings that have been made, whereby it becomes possible to close off the material from its precise position and further enhance the parallel precision and the dimensional precision of the opposed faces of the flanges.
  • Engagement holes for engagement with rotational shafts for rotatably supporting rotating bodies in the carrier may be made in pre-flanges before the material is closed off.
  • the parallel precision of the opposed faces of the flanges is not affected by the pressing force or the like generated at the time when the engagement holes are made.
  • the parallel precision of the opposed faces is further enhanced.
  • the engagement holes are made by forming the contour of the material and trimming it at the same time. Thus, the number of processes can be further reduced.
  • a wall surface at the axial center of the tubular material is bulged radially outwardly so that a pair of flanges opposed to each other and designed to rotatably support rotating bodies therebetween and joints for connecting the flanges are integrally formed.
  • the center of a tubular material is bulged, whereby a carrier having a pair of flanges opposed to each other and rotatably supporting rotating bodies therebetween and joints for connecting the flanges is manufactured easily.
  • the flanges and the joints are integrally formed from a single material with uninterrupted flow of the material, the number of parts is reduced and the processes of assembling and bonding become unnecessary so that the carrier can be formed with a reduced number of processes.
  • the parallel precision of the opposed faces can be enhanced at a low cost, and the weight can be saved through high rigidity.
  • a carrier having a configuration wherein joints are integrated with the outer peripheries of the flanges is manufactured.
  • Openings may be made in pre-joints of the material before the material is bulged.
  • the outer peripheral end faces of the flanges are curved towards the inside of the openings when the material is bulged. That is, the openings are made in the joints without affecting the parallel precision of the opposed faces of the flanges.
  • the parallel precision of the opposed faces can be further enhanced.
  • Engagement holes for engagement with rotational shafts for rotatably supporting rotating bodies in the carrier are made in pre-flanges before the material is bulged.
  • the parallel precision of the opposed faces of the flanges is not affected by the pressing force or the like generated at the time when the engagement holes are made.
  • the parallel precision of the opposed faces can be further enhanced.
  • mandrels may be interposed in positions for mounting rotating bodies between the flanges so that the flanges are swaged towards the mandrels.
  • FIG. 1 is a plan view of a carrier according to one embodiment of the invention.
  • FIG. 2 is a cross-sectional view taken along a line II-II shown in FIG. 1.
  • FIG. 3 is a cross-sectional view of a carrier according to another embodiment of the invention.
  • FIG. 4 is a cross-sectional view of a carrier according to still another embodiment of the invention.
  • FIG. 5 is a plan view of a plate material for explaining a method of manufacturing a carrier according to the invention.
  • FIG. 6 is a cross-sectional view taken along a line VI-VI shown in FIG. 5.
  • FIG. 7 is a plan view of a state where a pilot hole and engagement holes are made in one pre-flange of the plate material shown in FIG. 5 and where auxiliary openings and reference holes are made in pre-joints of the plate material shown in FIG. 5.
  • FIG. 8 is a cross-sectional view taken along a line VIII-VIII shown in FIG. 7.
  • FIG. 9 is a plan view of a state where the engagement holes in the plate material shown in FIG. 7 are chamfered.
  • FIG. 10 is a cross-sectional view taken along a line X-X shown in FIG. 9.
  • FIG. 11 is a plan view of a state where the pilot holes in the plate material shown in FIG. 9 are formed into through-holes and where the engagement holes in the plate material shown in FIG. 9 are finished to a dimension allowing engagement with rotational shafts of rotating bodies.
  • FIG. 12 is a cross-sectional view taken along a line XII-XII shown in FIG. 11.
  • FIG. 13 is a plan view of a cup-shaped material that has been formed by bending and drawing the plate material shown in FIG. 11.
  • FIG. 14 is a cross-sectional view taken along a line XIV-XIV shown in FIG. 13.
  • FIG. 15 is a plan view of a state where a groove designed as a bending guide is formed on the border between pre-joints and the other pre-flange on the inner periphery of a wall of the cup-shaped material shown in FIG. 13.
  • FIG. 16 is a cross-sectional view taken along a line XVI-XVI shown in FIG. 15.
  • FIG. 17 is a plan view of a state where front-end openings in the wall of the cup-shaped material shown in FIG. 15 are preliminarily closed off at an appropriate angle from the groove so that the front-end openings are slightly shrunk radially inwardly.
  • FIG. 18 is a cross-sectional view taken along a line XVIII-XVIII shown in FIG. 17.
  • FIG. 19 is a plan view of a state where mandrels are inserted through the openings preliminarily closed off as shown in FIG. 17 so that the front-end openings in the wall are shrunk radially inwardly.
  • FIG. 20 is a cross-sectional view taken along a line IIX-IIX shown in FIG. 19.
  • FIG. 21 is a plan view of a state where engagement holes are made in the other flange of the material shown in FIG. 19.
  • FIG. 22 is a cross-sectional view taken along a line IIXII-IIXII shown in FIG. 21.
  • FIG. 23 is a plan view of a state where the engagement holes shown in FIG. 21 are chamfered.
  • FIG. 24 is a cross-sectional view which is taken along a line IIXIV-IIXIV shown in FIG. 23 and which also shows a chamfering machine according to one embodiment of the invention.
  • FIG. 25 is a plan view of a state where the engagement holes chamfered as shown in FIG. 23 are finished to a dimension allowing engagement with rotational shafts of rotating bodies.
  • FIG. 26 is a cross-sectional view taken along a line IIXVI-IIXVI shown in FIG. 25.
  • FIG. 27 is a plan view of a state where mandrels are inserted from openings made in the joints of the carrier shown in FIG. 25 through positions for mounting rotating bodies between both the flanges and where both the flanges are swaged towards the mandrels.
  • FIG. 28 is a cross-sectional view taken along a line IIXVIII-IIXVIII shown in FIG. 27.
  • FIG. 29 is a cross-sectional view of a pressing machine according to one embodiment of the invention in a state where the preliminarily closed-off material is being closed off.
  • FIG. 30 is a cross-sectional view of a pressing machine according to one embodiment of the invention in a state where the material shown in FIG. 29 has been closed off.
  • FIG. 31 is a cross-sectional view of a method of manufacturing a carrier according to a second embodiment of the invention.
  • FIG. 32 is a cross-sectional view of a method of manufacturing a carrier according to a third embodiment of the invention.
  • FIG. 33 is a cross-sectional view of a method of manufacturing a carrier according to a fourth embodiment of the invention.
  • FIG. 34 is a cross-sectional view of a method of manufacturing a carrier according to a fifth embodiment of the invention.
  • FIG. 35 is a cross-sectional view of a method of manufacturing a carrier according to a sixth embodiment of the invention.
  • FIG. 36 is a cross-sectional view of a method of manufacturing a carrier according to a seventh embodiment of the invention.
  • FIG. 37 is a cross-sectional view of a method of manufacturing a carrier according to an eighth embodiment of the invention.
  • FIG. 38 is a cross-sectional view of a method of manufacturing a carrier according to a ninth embodiment of the invention.
  • FIG. 39 is a cross-sectional view of a carrier according to the related art.
  • FIGS. 1, 2, show a carrier C for rotatably supporting planetary gears (not shown) as rotating bodies in a planetary gear unit of an automatic transmission employed in an automobile and the like as described above.
  • like reference numerals denote like or similar components.
  • the carrier C of the invention is integrally formed of a pair of flanges 1 , 2 and a plurality of joints 3 through plastic deformation of a single material.
  • the flanges 1 , 2 are opposed to each other and rotatably support rotating bodies therebetween.
  • the joints 3 connect both the flanges 1 , 2 .
  • a groove 4 is formed on the border between the flanges 1 , 2 and the joints 3 .
  • the carrier C has openings 5 for exposing planetary gears so that the planetary gears and the like are inserted into the carrier C among the joints 3 and that the planetary gears can engage ring gears (not shown).
  • Engagement holes 6 , 7 for rotatably supporting rotational shafts of rotating bodies are made in the flanges 1 , 2 of the carrier C respectively.
  • Each of the flanges 1 , 2 which constitute a pair, is formed generally in the shape of a disc.
  • through-holes 1 a , 2 a through which shafts (not shown) and sun gears (not shown) are inserted, are made at the centers of the flanges 1 , 2 respectively.
  • the flanges 1 , 2 of the invention function substantially in the same manner as the carrier plate 31 and the base plate 32 of the carrier C′ of the aforementioned related art.
  • a plurality of joints 3 are formed along outer peripheral edges of the flanges 1 , 2 in the direction parallel to an axis J-J so as to retain opposed faces of the flanges 1 , 2 at a predetermined distance.
  • joints 3 of the invention function substantially in the same manner as a plurality of columns 33 protruding towards the base plate 32 substantially in the direction parallel to the shafts from the outer periphery of the plate portion 3 a of the carrier plate 31 of the carrier C′ of the aforementioned related arts.
  • the flanges 1 , 2 respectively have the three engagement holes 6 , 7 for engagement with rotational shafts (not shown) for rotatably supporting planetary gears.
  • the three joints 3 are disposed along the outer peripheral edges of the flanges 1 , 2 substantially at the centers with respect to the circumferential direction of the engagement holes 6 , 7 .
  • reference holes 8 used as a positioning reference or the like are made in the joints 3 of the carrier C of this embodiment substantially at the centers with respect to the axial direction and the circumferential direction of the joints 3 .
  • the carrier C having such a structure can be formed through plastic deformation of a single material, for example, by spinning or drawing a plate material W using a tool such as a spatula or a press roller. Because the thus-formed carrier C is integrally formed of the flanges 1 , 2 and the joints 3 with uninterrupted flow of a material, it is possible to reduce the number of parts and form the carrier C with a reduced number of processes, namely, without the necessity of performing assembling and bonding processes. Furthermore, the parallel precision of the opposed faces of the flanges 1 , 2 can be enhanced at a low cost. Because the carrier demonstrates high rigidity, it is possible to reduce the thickness of the carrier and thus realize a structure allowing the weight saving of the carrier.
  • the groove 4 is preliminarily formed in a portion which is to be the inside of the carrier and which is to be a border between the joints 3 and at least one of the flanges 1 , 2 of the material W either along the entire circumference or discontinuously.
  • the carrier C according to the invention is not limited to this embodiment.
  • the carrier C employed in the planetary gear unit or the like of the automatic transmission of the automobile as mentioned above, it is possible to integrally form a boss 9 so that it continues from the through-hole 1 a or 2 a formed at the center of at least one of the flanges 1 , 2 as shown in FIG. 3 in case of necessity, and form a spline or a gear 10 in the integrally formed boss 9 as shown in FIG. 4.
  • the carrier C of the invention is not necessarily employed in a planetary gear unit of an automatic transmission for an automobile or the like. That is, the carrier C according to the invention is applicable to other purposes.
  • the thus-constructed carrier C of the invention eliminates the necessity to assemble the columns 33 of the carrier plate 31 with the base plate 32 as is the case with the carrier C′ of the related arts (see FIG. 39).
  • the parallel precision is not adversely affected by the forming tolerance or the assembling error of the carrier plate 31 and the base plate 32 .
  • the opposed faces of the flanges 1 , 2 are formed with a high degree of parallel precision.
  • FIGS. 5 through 28 show a case where the carrier C constructed as described above is manufactured.
  • the carrier C having the flanges 1 , 2 and rotatably supporting rotating bodies such as planetary gears between the flanges 1 , 2 is manufactured.
  • the plate material W is bent and drawn into the shape of a cup, whereby the flange 1 is formed substantially at the center of the plate material W and a wall 11 (e.g. see FIG. 14) is formed on the outer periphery of the flange 1 .
  • a front-end opening in the wall 11 formed of an outer peripheral end face Wa of the material W is closed off, and the joints 3 and the flange 2 are integrally formed so that they continue from the flange 1 .
  • the front-end opening of the material W formed into the shape of a cup or a tube (described later) is “closed off”, it is formed so as to be shrunk radially inwardly.
  • auxiliary openings 5 ′ e.g. see FIG. 11
  • the openings 5 through which rotating bodies or the like can be inserted into the carrier C are made in pre-joints ( 3 ) of the plate material W before the plate material W is bent and drawn into the shape of a cup
  • the engagement holes 6 for engagement with rotational shafts for rotatably supporting planetary gears designed as rotating bodies in the carrier C are made in at least one of pre-flanges ( 1 ).
  • the bending guide 4 is formed on the border between the joints 3 and at least one of the pre-flanges ( 1 ), ( 2 ) (e.g. see FIG.
  • closing-off mandrels 12 are inserted from the openings 5 made in the pre-joints ( 3 ) of the material W that has been bent and drawn into the shape of a cup (e.g. see FIG. 19).
  • the outer peripheral end face Wa of the cup-shaped material W is closed off so as to be shrunk radially inwardly.
  • swaging mandrels 13 are inserted into mounting positions of the rotating bodies between the flanges 1 , 2 from the openings 5 made in the joints 3 of the closed-off carrier C (e.g. see FIG. 27), and the flanges 1 , 2 are swaged towards the swaging mandrels 13 .
  • the plate material W of this embodiment is generally formed into the shape of a disc having a predetermined thickness as shown in FIGS. 5, 6. As indicated by chain lines in FIG. 5, the central portion of the plate material W corresponds to the pre-flange ( 1 ), and the outer peripheral edge of the plate material W corresponds to the pre-flange ( 2 ). An annular portion located between the central portion ( 1 ) and the outer peripheral edge ( 2 ) in the radial direction corresponds to the pre-joints ( 3 ).
  • a generally triangular pilot hole 1 a ′ is made at the center of the pre-flange ( 1 ) of the thus-formed plate material W, and three auxiliary holes 6 ′, which are to be the engagement holes 6 , are made around the pilot hole 1 a ′.
  • the auxiliary holes 6 ′ are set in a dimension slightly smaller than a dimension allowing engagement with the rotational shafts of the planetary gears.
  • the three auxiliary openings 5 ′ are made in the pre-joints ( 3 ) radially outwardly so as to correspond to the auxiliary holes 6 ′.
  • the three reference holes 8 are made at the centers in the circumferential direction of the auxiliary openings 5 ′ and slightly radially outwardly of the auxiliary openings 5 ′.
  • the radial dimension of the auxiliary openings 5 ′ is set to almost half of the width of the joints 3 (the distance between the flanges of the carrier). Then, more processes are performed to form the openings 5 through which planetary gears or the like can be inserted into the carrier C thus manufactured.
  • the plate material W is chamfered by press working, cutting operations or the like so that the peripheries of sides of the auxiliary holes 6 ′ which are to be the inside of the carrier C are inclined with a diameter gradually increasing towards the inside of the carrier C.
  • the dimension of the auxiliary holes 6 ′ made in advance changes because of the chamfering.
  • the chamfering means that the side of the auxiliary holes 6 ′ which is to be the inside of the carrier C is scraped off.
  • the plate material W is punched so that the periphery of the pilot hole 1 a ′ assumes a generally circular shape, and one of the through-holes 1 a through which shafts (not shown) and sun gears (not shown) are inserted is made.
  • a notch 14 as a mark is made in the circular through-hole 1 a for example for the purpose of detecting the rotational phase of the formed carrier C in the circumferential direction.
  • the chamfered auxiliary holes 6 ′ are finished into the engagement holes 6 having a dimension allowing engagement with the rotational shafts of the planetary gears.
  • the plate material W is bent and drawn into the shape of a cup by means of pressing or the like, and the flange 1 and the wall 11 extending substantially perpendicularly to the outer periphery of the flange 1 are formed.
  • the wall 11 constitutes the joints 3 and the other flange 2 .
  • the auxiliary openings 5 ′ made in advance have almost half of the height of the pre-joints ( 3 ) extending from the outer peripheral edge of the flange 1 to the wall 11 .
  • the auxiliary openings 5 are punched on the front-end side of the wall 11 to a predetermined height and formed into the openings 5 .
  • the groove 4 designed as a bending guide is formed on the border between the pre-flange ( 2 ) and the pre-joints ( 3 ) on the inner periphery of the wall 11 either along the entire circumference or discontinuously.
  • the wall 11 is preliminarily closed off at an appropriate angle from the groove 4 so that the front-end opening in the wall 11 (the outer peripheral end face Wa of the material W) is slightly shrunk radially inwardly.
  • each of the closing-off mandrels 12 is inserted from one of the openings 5 to another one adjacent thereto so as to be close to a corresponding one of the joints 3 , and pressed by a pressing machine shown in FIGS. 29, 30.
  • the material W is then closed off so that the front-end opening in the wall 11 (the cup-shaped opening defined by the outer peripheral end face Wa of the material W) is shrunk radially inwardly, until the pre-flange ( 2 ) becomes parallel to the flange 1 .
  • the pressing machine has an upper mold 40 and a lower mold 41 , which are vertically movable relative to each other.
  • the upper mold 40 has a punch 42 , which presses the front-end opening Wa of the preliminarily closed-off material W when the upper mold 40 is relatively close to the lower mold 41 .
  • the lower mold 41 has a die 43 for accommodating the preliminarily closed-off material W, an ejector 44 slidably fitted into the die 43 to support the material W, and an ejector rod 45 for vertically moving the ejector 44 in the die 43 .
  • the inner diameter of the die 43 is approximately equal to the diameter of a bottom of the cup-shaped material W, which is to be the flange 1 .
  • holes are made in the die 43 so as to correspond to the openings 5 made between the joints 3 of the material W.
  • the closing-off mandrels 12 can be inserted into the openings 5 in the material W through the holes (see FIG. 19).
  • the height of the closing-off mandrels 12 is approximately equal to the distance between the inner faces of the flanges 1 , 2 of the carrier C.
  • the material W is first accommodated in the die 43 with the upper mold 40 and the lower mold 41 being spaced apart from each other, and the closing-off mandrels 12 are inserted from the openings 5 .
  • the punch 42 presses the front-end opening Wa of the preliminarily closed-off material W as shown in FIG. 29.
  • the preliminarily closed-off material W is bent so that the front-end opening Wa of the material W is shrunk radially inwardly, until the wall 11 extends substantially at a right angle from the groove 4 , namely, until the wall 11 becomes parallel to the flange 1 .
  • the portions among the openings 5 in the circumferential direction constitute the joints 3
  • the portion ( 2 ) which substantially forms a right angle with the joints 3 and which extends parallel to the flange 1 constitutes the flange 2 . That is, the foregoing processes are performed to integrally form the joints 3 and the flange 2 so that they continue from the flange 1 .
  • the closed-off front-end opening (the outer peripheral end face Wa) constitutes the through-hole 2 a through which a shaft (not shown) or a sun gear (not shown) is inserted.
  • a shaft not shown
  • a sun gear not shown
  • especially the front-end opening Wa of the closed-off material W generally tends to be crimpled because the material is compressed in the circumferential direction by being shrunk.
  • the material W is thick enough to demonstrate rigidity for preventing especially the front-end opening Wa from being crimpled but is thin enough to sufficiently save the weight of the carrier C.
  • the pre-flange ( 2 ) of the wall 11 is pressed so as to be sandwiched between the closing-off mandrels 12 and the punch 42 as shown in FIG.
  • the material W is prevented from being crimpled. Because the auxiliary openings 5 ′ and the openings 5 are made in advance before the material W is bent and drawn, the end faces of the flanges 1 , 2 facing the openings 5 are not curved so as to face each other. Because the flanges 1 , 2 and the joints 3 are integrally formed with uninterrupted flow of the material W, the carrier C is formed with high rigidity. For this reason, the flanges 1 , 2 and the joints 3 can be made relatively thin, whereby it becomes possible to save the weight of the carrier C. After the material W has been closed off, the upper mold 40 and the lower mold 41 are moved away from each other. The ejector 44 is then raised with respect to the die 43 by driving the ejector rod 45 , and the thus-formed carrier C is fetched from the die 43 .
  • auxiliary holes 7 ′ are made in the flange 2 of the carrier C so as to correspond to the engagement holes 6 made in the flange 1 .
  • the auxiliary holes 7 ′ are set in a dimension slightly smaller than a dimension allowing engagement with the rotational shafts of the planetary gears.
  • the engagement holes 6 in the flange 1 as shown in FIGS. 21, 22
  • the material W is chamfered so that the peripheries of sides of the auxiliary holes 7 ′ which are to be the inside of the carrier C are inclined with a diameter gradually increasing towards the inside of the carrier C.
  • the auxiliary holes 7 ′ can be chamfered using a chamfering machine 20 as shown in FIG. 24.
  • the chamfering machine 20 has a master cam member 21 inserted into the carrier C through one of the openings 5 , an auxiliary cam member 22 longitudinally movably supported in the master cam member 21 , and a chamfering punch 23 protruded from the master cam member 21 by the auxiliary cam member 22 .
  • One end face 21 a of the master cam member 21 is inclined in the shape of a cam so that the chamfering punch 23 moves into the opening 5 and faces a corresponding one of the auxiliary holes 7 ′ as a cam 24 moves vertically.
  • the chamfering punch 23 which faces one of the engagement holes 7 to be chamfered, is retained at the other end of the master cam member 21 such that the chamfering punch 23 can protrude therefrom.
  • End faces 22 a, 22 b of the auxiliary cam member 22 are inclined in the shape of a cam, and an insertion hole 21 c is made in the master cam member 21 at the end on the side of the cam-shaped end face 21 a so that a cam 25 can press the cam-shaped end face 22 a of the auxiliary cam member 22 .
  • an end face 23 a of the chamfering punch 23 located in the master cam member is inclined in the shape of a cam so as to correspond to the inclination of the end face 22 b of the auxiliary cam member 22 .
  • the other end face 23 b of the chamfering punch 23 is formed so as to correspond to a shape into which the engagement holes 7 are chamfered.
  • the master cam member 21 is disposed so as to correspond to one of the openings 5 between the joints 3 . If the cam-shaped end face 21 a of the master cam member 21 is pressed by the cam 24 that is vertically driven by a pressing machine (not shown), the chamfering punch 23 moves so as to match a corresponding one of the unchamfered auxiliary holes 7 ′ and the master cam member 21 is inserted into a space between the flanges 1 , 2 through the opening 5 of the joints 3 .
  • the cam-shaped end face 22 a of the auxiliary cam member 22 on the side of the insertion hole 21 c is not being pressed by the cam 25 . Accordingly, the chamfering punch 23 is accommodated in the master cam member 21 without protruding therefrom.
  • the swaging mandrels 13 have parallel faces which are opposed to the flanges 1 , 2 .
  • the width (height) of the faces is set so as to substantially coincide with a desired distance between the opposed faces of the flanges 1 , 2 of the carrier C.
  • the flanges 1 , 2 and the joints 3 are integrally formed and the opposed faces of the flanges 1 , 2 of the carrier C are swaged towards the swaging mandrels 13 , whereby it becomes possible to form the carrier C with high degrees of parallel precision and dimensional precision.
  • planetary gears are inserted into a space between the flanges 1 , 2 from the openings 5 , and the ends of rotational shafts of the planetary gears engage the engagement holes 6 , 7 made in the flanges 1 , 2 respectively.
  • the planetary gears are rotatably and stably supported with their rotational shafts being supported by both the flanges 1 , 2 which demonstrate a high degree of parallel precision.
  • FIG. 31 shows a method of manufacturing the carrier C according to a second embodiment of the invention.
  • FIG. 32 shows a third embodiment of the invention.
  • FIG. 33 shows a fourth embodiment of the invention.
  • FIG. 34 shows a fifth embodiment of the invention.
  • FIG. 35 shows a sixth embodiment of the invention.
  • FIG. 36 shows a seventh embodiment of the invention.
  • FIG. 37 shows an eighth embodiment of the invention.
  • FIG. 38 shows a ninth embodiment of the invention.
  • one of the through-holes 1 a through which a shaft (not shown) or a sun gear (not shown) is inserted, is first of all made at the center in one of pre-flanges ( 1 ) of the plate material W formed into a circular shape, and the plate material W is bent and drawn into the shape of a cup.
  • the opening 5 is made in a lower portion (of the drawing) in the wall 11 of the cup-shaped material W.
  • the groove 4 designed as a bending guide is formed in the inner periphery of the wall 11 of the material W on the border between the joint 3 and the other flange 2 . Then, as shown in FIG.
  • the outer peripheral portion of the flange 1 which faces the opening 5 is flattened.
  • the material W is preliminarily closed off at an appropriate angle from the groove 4 so that the front-end opening of the wall (the outer peripheral end face Wa of the material W) is slightly shrunk radially inwardly by means of spinning or the like.
  • the closing-off mandrels 12 are inserted from the openings 5 and the material W is pressed.
  • the material W is then closed off so that the front-end opening in the wall 11 (the outer peripheral face Wa of the material W) is shrunk radially inwardly, until the pre-flange ( 2 ) becomes parallel to the flange 1 .
  • the integral-type carrier C is formed so that the joints 3 for connecting the opposed flanges 1 , 2 continue therefrom.
  • one of the through-holes la through which a shaft (not shown) or a sun gear (not shown) is inserted, is first of all made at the center in one of pre-flanges ( 1 ) of the plate material W formed into a circular shape, and the plate material W is bent and drawn into the shape of a cup.
  • the groove 4 designed as a bending guide is formed in the inner periphery of the wall 11 of the cup-shaped material W in a portion which is to be the border between the joints 3 and the flange 2 . Then, as shown in FIG.
  • the material W is preliminarily closed off at an appropriate angle from the groove 4 so that the front-end opening in the wall 11 is slightly shrunk radially inwardly by means of spinning or the like. Then, as shown in FIG. 32D, the material W is closed off so that the front-end opening in the wall 11 (the outer peripheral face Wa of the material W) is shrunk radially inwardly, and the integral-type carrier C is formed so that the joints 3 for connecting the opposed flanges 1 , 2 continue therefrom. The openings 5 are thereafter made in the joints 3 (not shown).
  • one of the through-holes la through which a shaft (not shown) or a sun gear (not shown) is inserted, is first of all made at the center in one of pre-flanges ( 1 ) of the plate material W formed into the shape of a disc, and the openings 5 are made around the through-hole 1 a.
  • the plate material W is bent and drawn into the shape of a cup as shown in FIG. 33B, and the groove 4 designed as a bending guide is formed in the inner periphery of the wall 11 of the cup-shaped material W in a portion which is to be the border between the joints 3 and the flange 2 .
  • FIG. 33A one of the through-holes la, through which a shaft (not shown) or a sun gear (not shown) is inserted, is first of all made at the center in one of pre-flanges ( 1 ) of the plate material W formed into the shape of a disc, and the openings 5 are made around the through-hole 1 a.
  • the plate material W is bent and
  • the material W is preliminarily closed off at an appropriate angle from the groove 4 so that the front-end opening in the wall 11 is slightly shrunk radially inwardly by means of spinning or the like, and the material W is then closed off so that the front-end opening in the wall 11 (the outer peripheral end face Wa of the material W) is shrunk radially inwardly.
  • the carrier C is integrally formed so that the joints 3 for connecting the opposed flanges 1 , 2 continue therefrom, as in the aforementioned embodiments.
  • one of the through-holes la through which a shaft (not shown) or a sun gear (not shown) is inserted, is first of all made at the center in one of pre-flanges ( 1 ) of the plate material W formed into the shape of a disc, and the openings 5 are made around the through-hole 1 a.
  • the groove 4 designed as a bending guide is formed in the inner periphery of the wall 11 of the plate material W in a portion which is to be the border between the joints 3 and the flange 2 .
  • FIG. 34A one of the through-holes la, through which a shaft (not shown) or a sun gear (not shown) is inserted, is first of all made at the center in one of pre-flanges ( 1 ) of the plate material W formed into the shape of a disc, and the openings 5 are made around the through-hole 1 a.
  • the groove 4 designed as a bending guide is formed in the inner periphery of the wall 11 of the plate material W in a portion which
  • the plate material W is bent from the groove 4 and drawn into the shape of a cup. That is, as long as the bending guide 4 of the invention is formed before the material W is closed off, the bending guide 4 may be formed before the plate material W is bent and drawn into the shape of a cup.
  • the wall 11 formed by bending and drawing the material W constitutes only the flange 2 .
  • the material W is closed off so that the front-end opening in the wall 11 (the outer peripheral end face Wa of the material W) is shrunk radially inwardly.
  • the integral-type carrier C is formed so that the joints 3 for connecting the opposed flanges 1 , 2 continue therefrom.
  • a tubular material W is prepared in the sixth embodiment.
  • the openings 5 are first of all made at the axial centers in the tubular material W.
  • the tubular material W is formed into the shape of a cup by closing off one end thereof as shown in FIG. 35B.
  • the other end Wa of the material W which is a cup-shaped opening, is closed off, whereby the opposed flanges 1 , 2 and the joints for connecting them are integrally formed.
  • both the ends of the tubular material W are sequentially closed off, they are preliminarily closed off as described above.
  • the openings 5 may not necessarily be made at the outset.
  • the openings 5 may also be made after one or the other end of the tubular material W has been closed off.
  • a groove designed as a bending guide is formed in the inner periphery of the material W in a portion which is to be the border between the joints 3 and the flange 2 .
  • the groove may also be formed in the inner periphery of the tubular material W in a portion which is to be the border between the flange 1 and the joints 3 before the material W is formed into the shape of a cup by closing off one end thereof to form the flange 1 .
  • the auxiliary holes 6 ′, 7 ′ which are to be the engagement holes 6 , 7 for engagement with rotational shafts of planetary gears, may be made in advance in the tubular material W.
  • the tubular material W with the openings 5 made in its axial centers is prepared as shown in FIG. 36A.
  • the seventh embodiment is different from the sixth embodiment in that both the ends Wa of the tubular material W are closed off simultaneously. That is, as shown in FIG. 36B, both the ends Wa of the tubular material W are preliminarily closed off at the same time. Furthermore, as shown in FIG. 36C, both the ends Wa are closed off simultaneously, whereby the opposed flanges 1 , 2 are formed.
  • the axial centers of the tubular material W, which are not closed off, constitute the joints 3 for integrally connecting the flanges 1 , 2 .
  • a rod material W is prepared as shown in FIG. 37A.
  • the rod material means a material which has a predetermined length (predetermined thickness) L in the axial direction of the carrier so as to be formed into the shape of a cup by backward extrusion or the like and which is thicker than the aforementioned plate material.
  • the rod material W is first of all formed into the shape of a cup by backward extrusion or the like. Thereafter, as shown in FIG. 37C, one of the through-holes 1 a, through which a shaft (not shown) or a sun gear (not shown) is inserted, is made in the bottom of the cup-shaped material W.
  • the cup-shaped opening Wa is then closed off, whereby the opposed flanges 1 , 2 and the joints 3 for connecting them are integrally formed as shown in FIG. 37D.
  • the openings 5 among the joints 3 and the like can be made after the rod material W has been formed into the shape of a cup.
  • the joints 3 are formed by bulging the axial centers of the tubular material W radially outwardly, and accordingly, the flanges 1 , 2 are integrally formed so as to be opposed to each other and extend from the joints 3 radially inwardly.
  • FIG. 38 shows a mechanical bulging machine for bulging the tubular material. In FIG. 38, while the material has not been bulged on the left side with respect to a center line indicated by a chain line, the material has been bulged on the right side with respect to the center line.
  • the bulging machine according to one embodiment of the invention will be described with reference to FIG. 38.
  • This bulging machine has an upper mold 50 and a lower mold 51 which are vertically movable relative to each other, punches 52 for pressing the tubular material W so as to bulge its axial centers, and a cam mechanism 53 for driving the punches 52 radially outwardly.
  • the upper mold 50 is supported by a vertical-drive rod 54 so that the upper mold 50 vertically moves relative to the lower mold 51 .
  • Receptacles 50 a , 51 a for receiving the tubular material W and cavities 50 b , 51 b for determining the configuration of the bulged material are formed in a butt face which is formed when the upper mold 50 and the lower mold 51 are closed.
  • the punches 52 are divided in the radial direction of the material W and radially slidably supported by punch plates 55 disposed inwardly of the receptacle 50 a of the upper mold 50 .
  • a punch holder 56 is disposed below the punches 52 .
  • a receptacle 57 which receives the punch holder 56 when the upper mold 50 and the lower mold 51 are butted against each other, is formed inwardly of the receptacle 51 a of the lower mold 51 .
  • a stopper 52 a protrudes from a radially intermediate position on the lower surface of each of the punches 52 .
  • Stoppers 56 a, 56 b are formed at radially inner and outer positions on the upper surface of the punch holder 56 .
  • a spring 58 is interposed between the stopper 52 a of each of the punches 52 and the radially outer stopper 56 a of the punch holder 56 so as to urge each of the punches 52 to retract radially inwardly.
  • the cam mechanism 53 drives each of the punches 52 radially outwardly against the urging force of the spring 58 and is composed of a cam face 52 b formed radially inwardly of each of the punches 52 and a cam member 59 bonded to the cam face 52 b .
  • the upper end of the cam member 59 is connected to a drive plate 60 .
  • the vertical-drive rod 54 is inserted through the drive plate 60 so as to vertically drive the drive plate 60 relative to the upper mold 50 .
  • the holes 5 ′ which are to be the openings 5 , are made in advance in the axial centers of the tubular material W.
  • the dimension of the holes 5 ′ is set in accordance with the dimension of the openings 5 .
  • the invention is not limited to the aforementioned embodiments. It is possible to employ a hydraulic bulging machine (not shown) instead of the mechanical one. In this case, a working fluid is supplied into a tubular material at a predetermined pressure. Therefore, the tubular material is sealed to prevent the working fluid from leaking out from the holes which are made in advance in the axial centers of the tubular material and which are to be the openings 5 . Alternatively, the holes which are to be the openings 5 are not made in advance in the tubular material, and the openings 5 are made in the material after it has been bulged.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Details Of Gearings (AREA)
  • Shaping Metal By Deep-Drawing, Or The Like (AREA)
  • Retarders (AREA)
  • Fittings On The Vehicle Exterior For Carrying Loads, And Devices For Holding Or Mounting Articles (AREA)
US09/783,992 2000-02-16 2001-02-16 Carrier and method of manufacturing carrier Abandoned US20010018381A1 (en)

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JP2000-038561 2000-02-16
JP2000365175A JP3826995B2 (ja) 2000-02-16 2000-11-30 キャリヤの製造方法

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US10/689,613 Expired - Fee Related US7100416B2 (en) 2000-02-16 2003-10-22 Carrier and method of manufacturing carrier

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EP (1) EP1146254B1 (ko)
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WO2003076825A2 (en) * 2002-03-05 2003-09-18 Metal Forming & Coining Corporation Pinion carrier for planetary gear train and method of making same
WO2003076825A3 (en) * 2002-03-05 2004-02-19 Metal Forming & Coining Corp Pinion carrier for planetary gear train and method of making same
US6863636B2 (en) 2002-03-05 2005-03-08 Metal Forming & Coining Corporation Pinion carrier for planetary gear train and method of making same
US20070051156A1 (en) * 2005-08-31 2007-03-08 Aisin Aw Co., Ltd. Manufacturing method for an annular member and a pronged annular member
US20110009233A1 (en) * 2008-03-11 2011-01-13 Toyota Jidosha Kabushiki Kaisha Carrier assembly for supporting pinion gears
US8900089B2 (en) 2008-03-11 2014-12-02 Toyota Jidosha Kabushiki Kaisha Carrier assembly for supporting pinion gears
US10378643B2 (en) * 2014-12-03 2019-08-13 Schaeffler Technologies AG & Co. KG Planetary drive comprising a planet carrier

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US20040082432A1 (en) 2004-04-29
CN1309039A (zh) 2001-08-22
DE60109978T2 (de) 2006-02-23
EP1146254A3 (en) 2002-07-10
EP1146254B1 (en) 2005-04-13
EP1146254A2 (en) 2001-10-17
CN1252402C (zh) 2006-04-19
US7100416B2 (en) 2006-09-05
KR20010082655A (ko) 2001-08-30
JP3826995B2 (ja) 2006-09-27
DE60109978D1 (de) 2005-05-19
JP2001343064A (ja) 2001-12-14
KR100413263B1 (ko) 2003-12-31

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