Spherical Clutch Torque Converter Misalignment Compensation
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Solution Overview
Problem
Existing torque converters face misalignment issues during operation, leading to undesirable torque fluctuations, and have large torus sizes that contribute to increased weight, affecting fuel economy.
Innovation Solution
A spherical clutch arrangement with first and second spherical centers along the axis of rotation, featuring frictional surfaces for engagement along a great circle, which self-centers and compensates for misalignment, reducing torus size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional clutch arrangements are used in torque converters, then the structure is simpler to manufacture, but misalignment occurs during operation leading to torque fluctuations
Solution Approach 1:
The patent applies spherical surfaces to the clutch members, where the friction surfaces are formed on spherical segments rather than flat surfaces. This curvature allows the clutch members to self-align during engagement, compensating for misalignment and eliminating torque fluctuations while maintaining reliable torque transmission.
Solution Approach 2:
The clutch members are designed with asymmetric spherical geometries where the spherical centers are offset from each other. This asymmetric arrangement creates a self-centering mechanism that automatically compensates for alignment errors during operation, improving torque consistency without requiring complex alignment systems.
2Reliability
If larger torus sizes are used in torque converters, then the clutch engagement surface area is increased, but the weight increases affecting fuel economy
Solution Approach 1:
The spherical geometry of the clutch members concentrates the friction engagement on a focused contact zone along the great circle, allowing for reliable torque transmission with smaller overall component sizes. This reduces the torus size and consequently the weight of the torque converter while maintaining engagement reliability.
Solution Approach 2:
The friction material is applied selectively on specific portions of the spherical surfaces where contact occurs during engagement. This localized application of friction material ensures reliable engagement while minimizing the overall size and weight of the clutch components, avoiding unnecessary material usage.
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 spherical clutch assembly provides consistent torque performance, misalignment compensation, and reduced weight, enhancing fuel economy by ensuring even contact and alignment of frictional surfaces.
Implementation Method 1
a first frictional surface; a second frictional surface... wherein the first and second frictional surfaces are arranged for frictional engagement
Data Source
AI summary
A clutch assembly comprising: an axis of rotation; first and second spherical centers positioned along the axis of rotation; a first member having a first spherical surface including: a radius defining a first curvature; the first spherical center; and a first frictional surface; a second member having a second spherical surface including: said radius defining a second curvature about same or equal to the first curvature; the second spherical center; and a second frictional surface. A torque converter comprising a spherical clutch assembly is also disclosed.