Stamped Torque Converter Lug Design for Durability
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Solution Overview
Problem
Existing torque converter lugs, typically made by machining or forging, lack durability and require costly welding processes, which can be inefficient and prone to failure under mechanical stress.
Innovation Solution
A stamped sheet metal lug design comprising radial segments and an axially extending connector segment, where the segments are joined by welding and feature apertures for fastener reception, enhancing structural integrity and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional machining or forging methods are used to manufacture lugs, then structural strength is maintained, but manufacturing cost increases and production efficiency decreases
Solution Approach 1:
The invention changes the manufacturing method from traditional machining or forging to stamping and welding processes. The lug is formed by stamping metal sheets into specific shapes and then welding multiple stamped segments together, fundamentally altering the manufacturing parameters while maintaining structural integrity through proper weld design and material selection
Solution Approach 2:
The lug is divided into multiple separate stamped segments that are subsequently welded together to form the complete lug structure. This segmentation allows each segment to be manufactured independently using efficient stamping processes, reducing overall manufacturing complexity and cost while enabling modular assembly
2Reliability
If welding processes are used to join lug segments, then structural integrity is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The lug is divided into multiple separate stamped segments that are subsequently welded together to form the complete lug structure. This segmentation allows each segment to be manufactured independently using efficient stamping processes, reducing overall manufacturing complexity and cost while enabling modular assembly
Solution Approach 2:
Multiple independently manufactured stamped segments are joined together through welding to create the complete lug structure. This merging process combines the advantages of efficient stamping manufacturing with the structural benefits of a integrated lug design, achieving both cost-effectiveness and structural integrity
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 stamped sheet metal lug design improves durability and manufacturing efficiency by providing a robust torque converter component with reduced material costs and simplified assembly, addressing the limitations of traditional machining or forging methods.
Implementation Method 1
the first and third circumferential ends are fixed together by welding, and the second and fourth circumferential ends are fixed together by welding
Data Source
AI summary
A lug for a torque converter includes a first radial segment, a second radial segment, and an axially extending connector segment. The first radial segment has a first aperture and respective first and second circumferential ends. The second radial segment has a second aperture aligned with the first aperture, a third circumferential end fixed to the first circumferential end, and a fourth circumferential end fixed to the second circumferential end. The axially extending connector segment joins the first and second radial segments. In an example embodiment, a pre-formed blank for the lug includes a line of symmetry passing through the connector segment.