Torque Converter Impeller Weld Groove for Stronger Hub Assembly
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Solution Overview
Problem
Existing torque converter assemblies face challenges in manufacturing and assembly due to complex connections between components, leading to high labor costs and assembly time.
Innovation Solution
The torque converter design incorporates an impeller with a rounded blade supporting portion, an inner radial portion, and an impeller hub, where the impeller hub is fixed to the outer surface of the inner radial portion via a weld formed partially in a groove stamped into the outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional connection methods are used between torque converter components, then assembly flexibility is maintained, but manufacturing complexity and labor costs increase significantly
Solution Approach 1:
The patent combines multiple connection functions into a single integrated weld groove structure on the impeller hub. The groove simultaneously provides positioning, alignment, and welding attachment features, eliminating the need for separate chamfers, countersinks, or multiple fastening elements. This merging of functions directly reduces manufacturing complexity while maintaining assembly effectiveness.
Solution Approach 2:
The weld groove structure serves multiple purposes: it acts as a positioning feature during assembly, provides a standardized welding surface for consistent attachment, and enables simplified connection geometry. This multi-functional design allows the same structural element to fulfill several connection requirements, reducing the overall number of components and operations needed.
2Productivity
If simplified connection structures are used, then assembly time is reduced, but connection strength and durability may be compromised
Solution Approach 1:
The patent optimizes the weld groove's geometric parameters (depth, width, angle, and positioning) to achieve the ideal balance between assembly simplicity and connection strength. By carefully controlling these parameters, the groove provides sufficient weld metal volume and stress distribution area to ensure durability, while maintaining a simple shape that enables rapid assembly and welding 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
This design reduces manufacturing and assembly costs by eliminating the need for a chamfer on the impeller hub and allowing increased weld penetration, which improves the durability of the welded connection without additional costly operations.
Implementation Method 1
The impeller hub is fixed to the outer surface of the inner radial portion via a weld formed partially in a groove stamped into the outer surface
Data Source
AI summary
An impeller for a torque converter includes a rounded blade supporting portion, an inner radial portion, and an impeller hub. The inner radial portion includes an inner radial end disposed radially inwardly of the rounded blade supporting portion and an outer surface extending from the rounded blade supporting portion to the inner radial end. The impeller hub is fixed to the outer surface of the inner radial portion via a weld. The outer surface includes a groove arranged to, at least partially, axially overlap the impeller hub. The weld is formed, at least partially, in the groove.