Lightweight and low noise gear assembly
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.
1 . A gear assembly comprising:
a shaft;
at least one disc; and
a ring gear component;
wherein two or more of the shaft, the at least one disc, and the ring gear component are welded together;
wherein the at least one disc comprises a dual disc configuration, the dual disc configuration comprising:
a first disc; and
a second disc, wherein the first disc and the second disc are oriented so that the first disc and the second disc cross each other;
wherein first radial ends of each of the first disc and the second disc are joined to the shaft, and each of second radial ends of each of the first disc and the second disc are joined to the ring gear, wherein a distal end of the second radial end of the first disc extends in an axial direction towards a first end of the shaft and a distal end of the second radial end of the second disc extends in an axial direction towards a second end of the shaft.
2 . The gear assembly of claim 1 , wherein the shaft, the at least one disc, and the ring gear component are welded together at a plurality of weld joints.
3 . The gear assembly of claim 1 , wherein the at least one disc comprises at least one of an ASTM A572 material and a 8620 steel material.
4 . The gear assembly of claim 1 , wherein the second disc has a same thickness as the first disc.
5 . The gear assembly of claim 1 , wherein a vibration noise of the gear assembly is in a range of 106-134 dB, wherein a first harmonic of the vibration noise is equal to about 134 dB, a second harmonic of the vibration noise is equal to about 123 dB, and a third harmonic of the vibration noise is equal to about 106 dB.
6 . A shaft assembly comprising:
a shaft extending between a first end and a second end;
a ring gear; and
at least one disc operatively coupling the ring gear to the shaft and extending between a first radial end proximate the shaft and a second radial end proximate the ring gear, wherein at least a distal end of the second radial end extends in an axial direction towards the shaft first end, and the distal end extending in the axial direction is joined to the ring gear;
wherein the at least one disc comprises a dual disc configuration, the dual disc configuration comprising:
a first disc; and
a second disc having a same thickness as the first disc;
wherein the first disc and the second disc are oriented so that the first disc and the second disc cross each other;
wherein the first disc and the second disc are formed from a single piece of steel.
7 . The shaft assembly of claim 6 , wherein the second radial end of the at least one disc is directly attached to the shaft.
8 . The shaft assembly of claim 7 , wherein the first radial end of the at least one disc is directly attached to the ring gear.
9 . The shaft assembly of claim 6 , wherein each of the first and second discs include first radial ends and second radial ends.
10 . The gear assembly of claim 9 , wherein the first radial ends of each of the first disc and the second disc are joined to the shaft, and each of second radial ends of the first and second discs are joined to the ring gear, and the distal end of the second radial end extends in an axial direction towards the second end of the shaft.