Interlocking Stator Assembly for Torque Converter Axial Retention
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Solution Overview
Problem
Existing stator assemblies for torque converters experience axial displacement and failure due to drag forces causing the side plate to rotate relative to other components, leading to instability during operation.
Innovation Solution
A stator assembly design featuring a side plate with a radially outer surface defining a slot, a one-way clutch axially disposed between the stator and side plate, and a washer with an annular body and axial protrusion extending past the annular body portion, which limits the rotation of the side plate by blocking its alignment with retaining tabs, thereby preventing axial displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a side plate is used to axially retain stator components, then axial retention is achieved, but drag forces cause the side plate to rotate relative to other components, resulting in axial displacement and failure
Solution Approach 1:
The side plate is segmented into multiple functional zones: an inner portion that rotates with the stator, an outer portion that remains stationary, and a connecting web portion. This segmentation allows different parts of the side plate to perform different functions - the inner portion follows the stator rotation while the outer portion maintains axial retention, preventing both rotation-induced displacement and axial instability
Solution Approach 2:
Different regions of the side plate are given different rotational characteristics. The inner portion is designed to rotate with the stator to accommodate drag forces locally, while the outer portion is constrained to remain stationary to maintain axial retention. This local differentiation of rotational properties resolves the contradiction between allowing rotation to accommodate drag forces and preventing rotation to maintain stability
2Force
If the side plate is allowed to rotate to accommodate drag forces, then stress distribution is improved, but axial displacement occurs leading to assembly failure
Solution Approach 1:
The side plate is divided into an inner rotating portion and an outer stationary portion connected by a web. The inner portion rotates to accommodate drag forces and distribute stress, while the outer portion remains stationary to maintain axial alignment. The web connection transmits forces between these portions, allowing stress distribution without axial displacement
Solution Approach 2:
The web portion acts as an intermediary element connecting the inner rotating portion to the outer stationary portion. It mediates the transmission of drag forces from the rotating stator to the stationary outer portion, allowing the inner portion to rotate freely while the outer portion maintains axial position, thus accommodating drag forces without losing axial alignment
Data Source
AI summary
A torque converter, including: a cover arranged to receive torque and supported for rotation around an axis of rotation; an impeller including an impeller shell connected to the cover and at least one impeder blade; a turbine in fluid communication with the impeller and including a turbine shell and at least one turbine blade; and a stator assembly including a stator including a plurality of stator blades, a side plate including a radially outer surface defining a slot, a one-way clutch axially disposed between the stator and the side plate, and a washer including an annular body portion in contact with the side plate, and an axial protrusion extending past the annular body portion in a first axial direction parallel to the axis of rotation, and disposed in the slot.