Torque Converter Impeller Groove for Weld Durability
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Solution Overview
Problem
Existing torque converter impellers face challenges in durability due to the rigidity of the impeller shell, which affects the strength and reliability of the weld between the impeller hub and shell.
Innovation Solution
Incorporating an axially extending groove in the radial extension of the impeller shell, which is machined to create a flexible thinned section, allowing for a more robust weld by adding flexibility to the impeller shell and positioning the weld radially inside the groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the impeller shell is made rigid to maintain structural stability, then the structural stability is improved, but the weld durability between impeller hub and shell deteriorates
Solution Approach 1:
The impeller shell transitions from a uniformly rigid structure to a non-uniform structure with a localized flexible section. The flexible section is created by forming a groove in the radial extension of the impeller shell, which localizes flexibility where needed while maintaining rigidity in other areas. This allows the weld between the impeller hub and shell to accommodate thermal expansion and contraction stresses, improving weld durability without compromising overall structural stability.
Solution Approach 2:
The physical parameter of the impeller shell is changed from uniform rigidity to a combination of rigid and flexible regions. By modifying the thickness and geometry of the radial extension through groove formation, the shell creates a flexible section that can deform elastically during operation. This parameter change allows the structure to absorb thermal and mechanical stresses, preventing weld failure while maintaining overall structural integrity.
2Reliability
If the impeller shell is made flexible to improve weld durability, then the weld durability is improved, but the structural stability deteriorates
Solution Approach 1:
The flexibility is localized to a specific radial extension section through groove formation, rather than making the entire impeller shell flexible. This localized flexible section acts as a stress-absorbing element that protects the weld, while the rest of the impeller shell maintains its rigid structural stability. The groove creates a hinge-like flexible section with controlled deformation characteristics.
3Reliability
If a groove is formed in the radial extension to create flexibility, then the weld durability is improved, but the device complexity increases
Solution Approach 1:
The groove is formed by modifying the geometric parameters of the radial extension, specifically by removing material to create a controlled flexible section. This parameter change (geometry modification) achieves the desired flexibility without requiring additional components, assemblies, or complex structural elements. The flexible section is created through straightforward machining or forming operations.
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 added flexibility improves the durability of the impeller hub weld, enhancing the structural integrity and reliability of the torque converter impeller.
Implementation Method 1
The impeller includes an impeller hub welded to the impeller shell by a weld
Data Source
AI summary
An impeller for a torque converter is provided. The impeller includes an impeller shell including an inner circumference, an outer circumference and a radial extension extending radially outward from the inner circumference. The radial extension includes an axially extending groove formed therein. The impeller also includes an impeller hub welded to the impeller shell by a weld. The weld is radially inside of the axially extending groove. A method of forming an impeller for a torque converter is also provided.