Torque Converter Stator Pocket Design for Axial Deflection Control
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Solution Overview
Problem
Torque converter stators experience unpredictable deflection of the stator hat and brim during the axial pressing of the outer race into the stator body, which can lead to contact with the core ring and affect the torque converter's performance.
Innovation Solution
A pocket is designed radially outside of the one-way clutch within the stator body to minimize deflection by relocating it to the pocket area, reducing weight and inertia, and preventing contact with the core ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the outer race is axially pressed into the stator body, then the one-way clutch is assembled into the stator, but unpredictable deflection of the stator hat and brim occurs causing contact with the core ring
Solution Approach 1:
The invention extracts the problematic hat and brim structures from the stator body by designing them as separate, removable components. This allows the outer race to be pressed into the stator body without causing unpredictable deflection of integrated hat and brim structures, thereby eliminating contact with the core ring while maintaining assembly feasibility.
Solution Approach 2:
The stator is segmented into distinct components: the stator body, the hat, and the brim. This segmentation allows each component to be independently designed and assembled, preventing the unpredictable deflection that occurs when hat and brim are integrated into the stator body during the pressing operation.
2Strength
If the stator hat and brim are made thick to prevent deflection, then structural strength is improved, but weight and inertia increase
Solution Approach 1:
By extracting the hat and brim from the stator body as separate components, the invention eliminates the need for excessive thickness in these structures to prevent deflection during assembly. The separate components can be designed with optimal thickness for strength while minimizing weight, as they are not subjected to the same pressing forces as an integrated structure.
Solution Approach 2:
The invention applies local quality by providing reinforcement only where needed - specifically in the stator body where the outer race is pressed in. The hat and brim, being separate components, do not require excessive thickness since they are not subjected to the same assembly forces, thereby reducing overall weight while maintaining necessary strength.
Data Source
AI summary
A stator for a torque converter is provided. The stator includes a plurality of blades, a one-way clutch and a body supporting the blades. The body receives the one-way clutch therein and includes a pocket formed therein radially outside of the one-way clutch. A method of forming a torque converter is also provided. The method includes forming a pocket in a body of a stator. The stator includes a plurality of blades supported by the body. The body includes a recess radially inside of the pocket. The method also includes axially pressing an outer race of a one-way clutch into the recess. A torque converter is also provided.