Double Spine Ring Adapter for Faster Torque Converter Testing
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Solution Overview
Problem
The lack of adaptability in the manufacturability of the inner ring of a one-way clutch in torque converters leads to delays in performance tests, as special tooling is often not available, requiring extensive development time for each new spline configuration, resulting in prolonged delays in benchmarking developments.
Innovation Solution
A spline adapter assembly that includes an inner race ring with a radially outer roller body contact surface and a complementary adapter, allowing for faster adaptation of torque converter components and test equipment by machining or using stock adapter rings, reducing the time required to create interface tooling from 12-14 weeks to 1-2 weeks and enabling easier maintenance through laser-cut steel sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If special tooling is developed for each new spline configuration, then testing accuracy is improved, but development time increases significantly (12-14 weeks)
Solution Approach 1:
The adapter assembly is divided into separate components: an adapter body with a standardized shaft interface and configurable spline interfaces. This segmentation allows the spline configuration to be changed independently without redesigning the entire tooling assembly, reducing development time while maintaining testing accuracy.
Solution Approach 2:
The adapter is designed with a universal shaft interface that can accommodate multiple spline configurations. By making the adapter body reusable and configurable, it serves multiple testing purposes across different torque converter designs, eliminating the need for completely new tooling for each configuration.
2Reliability
If custom tooling is manufactured for each torque converter configuration, then test reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The adapter assembly serves as a universal interface between the test equipment shaft and various torque converter configurations. The standardized shaft interface and configurable spline interfaces allow one adapter design to handle multiple testing scenarios, reducing overall tooling complexity while maintaining test reliability.
Solution Approach 2:
The adapter acts as an intermediary component between the fixed test equipment shaft and the variable torque converter configurations. This mediator absorbs the complexity of adapting to different configurations, leaving the core test equipment simple and reusable.
3Manufacturing precision
If complete tooling development is performed for new splines, then interface precision is improved, but production time increases (12-14 weeks to 1-2 weeks)
Solution Approach 1:
The adapter is segmented into a standardized body and configurable spline interfaces. This allows only the necessary spline portions to be manufactured or adjusted, rather than producing entirely new tooling, thereby maintaining interface precision while dramatically reducing production time from 12-14 weeks to 1-2 weeks.
Solution Approach 2:
The adapter body is pre-manufactured with a standardized shaft interface that ensures precise alignment and connection. This preliminary preparation of the critical interface components allows for rapid configuration changes without compromising precision, as the precision-critical elements are already in place.
Data Source
AI summary
A spline adapter assembly for connecting a torque converter one-way clutch to a shaft for testing. The spline adapter assembly includes an inner race ring including a radially outer roller body contact surface and a radially inner interface surface, and an adapter having a radially outer interface surface that is complementary to and engaged with the radially inner interface surface of the inner race ring and a radially inner shaft interface surface. The inner race ring of the spline adapter assembly replaces the original inner one-way clutch race ring and can be machined for each assembly being tested in order to provide the proper radially outer roller body contact surface configuration, and is connected to a universal adapter that mates with the test equipment.