Integral Flexplate for Engine Transmission Coupling
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Solution Overview
Problem
In automotive applications, coupling an engine to a transmission from a different manufacturer is challenging due to misalignment and compatibility issues, leading to complex and time-consuming assembly processes, potential for component loss, and increased risk of bolt loosening and failure under high loads and vibrations.
Innovation Solution
A single, integral flexplate with specific borings and apertures for both engine and transmission interfaces, eliminating the need for adaptors and spacers, and ensuring proper alignment and secure mounting through a unified design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple adaptor components are used to couple unrelated engine and transmission, then compatibility between different manufacturers' components is achieved, but device complexity and assembly time increase significantly
Solution Approach 1:
The patent combines multiple separate adaptor components (adaptor plate, spacer, mounting hubs) into a single integrated flexplate component. This unified design maintains the ability to couple unrelated engine and transmission while eliminating the complexity of assembling multiple separate parts, directly resolving the technical contradiction between adaptability and device complexity.
2Adaptability or versatility
If multiple adaptor components are used to accommodate misalignment, then compatibility between different manufacturers' components is achieved, but the risk of component loss and misalignment increases
Solution Approach 1:
The integrated flexplate design eliminates multiple separate adaptor components that could be lost or misaligned during assembly. By combining all alignment and mounting functions into a single precision-machined component with specifically positioned borings and apertures, the system maintains compatibility while significantly improving assembly reliability.
3Strength
If multiple bolted connections are used to secure adaptor components, then secure mounting is achieved, but the risk of bolt loosening under high loads and vibrations increases
Solution Approach 1:
The patent reduces multiple separate bolted connections across several adaptor components to a single bolted connection securing the integrated flexplate to the crankshaft flange. This unified mounting approach maintains secure attachment under high loads and vibrations while eliminating the cumulative failure risks associated with multiple separate connections.
4Adaptability or versatility
If adaptors and spacers are used to mate unrelated transmission to engine, then compatibility is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The integrated flexplate consolidates all alignment functions into a single component that is precision-machined as one unit. This approach maintains compatibility between unrelated engine and transmission while reducing the cumulative tolerance stack-up that occurs when assembling multiple separate adaptors, thereby lowering overall manufacturing precision requirements.
Data Source
AI summary
A flexplate comprising a single integral body portion having a generally circular shape. One or more borings are formed in the body portion for receiving an end of a crankshaft of the engine on a first side of the body portion and for receiving a torque converter of an unrelated transmission on a second side of the body portion. Apertures may be formed in the body portion and positioned on the flexplate for alignment with corresponding apertures on a flange mounted to the end of the crankshaft and apertures on the torque converter.