Multi-Plate Flow Channel Structure for Low-Cost Torque Converter Oil Routing
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Solution Overview
Problem
The existing flow channel structures for torque converters, which involve forging metal materials into block shapes with obliquely extending channels, are costly to manufacture and require complex processes.
Innovation Solution
A flow channel structure composed of multiple plates with strategically positioned through holes, allowing for communication between fluid chambers without the need for forging, enabling a more cost-effective manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal material is forged into a block shape with obliquely extending flow channel, then the flow channel structure can make fluid chambers communicate effectively, but the manufacturing cost becomes high
Solution Approach 1:
The flow channel structure is divided into multiple separate plates (first plate, second plate, third plate) instead of being forged as a single block. Each plate contains specific through-holes that align to form the complete flow channel path, enabling cost-effective manufacturing while maintaining fluid communication functionality.
Solution Approach 2:
The flow channel is formed by arranging through-holes in different plates at different positions when viewed from the thickness direction. This multi-dimensional arrangement of through-holes across stacked plates creates the oblique flow path without requiring complex forging operations.
2Reliability
If metal material is forged into a block shape with obliquely extending flow channel, then the flow channel structure can make fluid chambers communicate effectively, but the manufacturing process becomes complex
Solution Approach 1:
The monolithic forged block is segmented into multiple simple plates that can be manufactured using standard drilling and punching operations. Each plate is relatively simple in structure, and the complex oblique flow channel is achieved through the arrangement of simple through-holes across multiple plates rather than complex forging.
3Ease of manufacture
If through holes are positioned at different locations in stacked plates, then cost-effective manufacturing is enabled, but proper alignment for fluid communication must be achieved
Solution Approach 1:
The alignment of through-holes is achieved by positioning them at different locations when viewed from the thickness direction (axial direction). The through-holes in different plates are arranged so that they align when the plates are stacked, forming the complete oblique flow channel path without requiring complex precision forging.
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 configuration allows for the creation of a low-cost flow channel structure that effectively communicates between fluid chambers, reducing manufacturing costs while maintaining functionality in torque converters.
Implementation Method 1
When the hydraulic oil in the second fluid chamber is increased in pressure, the piston is axially moved
Data Source
AI summary
A flow channel structure forms a first flow channel which makes a first fluid chamber and a second fluid chamber communicate with each other therethrough. The flow channel structure includes first to third plates. The first plate includes a first through hole penetrating the first plate in a thickness direction to open to the first fluid chamber. The second plate includes a second through hole penetrating the second plate in the thickness direction to open to the second fluid chamber. The third plate includes a first connecting through hole penetrating the third plate in the thickness direction. The first connecting through hole is larger in flow channel area than each of the first and second through holes. The first and second through holes are disposed in different positions from each other as seen in the thickness direction. The first connecting through hole communicates with the first and second through holes.