Torque Converter Cover Compensator for Charge Pressure Deflection
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Solution Overview
Problem
During gear changes in automatic transmissions, the charge pressure in torque converters can cause the cover to deflect, leading to unpredictable torque passing and potential mechanical slippage due to the direct integral connection between the impeller and front cover, which results in pressure imbalances and mechanical inefficiencies.
Innovation Solution
A cover compensator is introduced between the front cover and the impeller, which includes a sealing surface to engage with the transmission input shaft and fluidly couples chambers on either side, maintaining pressure equilibrium and reducing deflection by acting as an intermediary to compensate for charge and rotational pressures, thereby stabilizing the torque converter during gear changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the impeller is directly integral connected to the front cover, then the structural simplicity is improved, but the cover deflection and torque transmission stability deteriorate under charge pressure during gear changes
Solution Approach 1:
The direct integral connection between the front cover and impeller is segmented by introducing a cover compensator as a separate component. The cover compensator includes a front cover, impeller, and a compensator plate that can independently deflect under charge pressure, thereby preventing stress concentration and maintaining torque transmission stability while preserving structural simplicity.
Solution Approach 2:
A cover compensator acts as an intermediary component between the front cover and impeller. This compensator includes a compensator plate that can deflect under charge pressure, absorbing the stress and preventing direct transmission of pressure-induced deflections to the impeller, thus maintaining reliable torque transmission while keeping the overall structure simple.
2Reliability
If the cover compensator is added between the front cover and impeller, then the torque transmission stability is improved, but the device complexity increases
Solution Approach 1:
The cover compensator is designed as a segmented structure with a front cover, impeller, and compensator plate that can independently deflect. This segmentation allows the compensator to absorb charge pressure-induced stresses without requiring complex additional components, thereby improving torque transmission stability while minimizing structural complexity.
Solution Approach 2:
The cover compensator serves multiple functions: it acts as a structural connector between the front cover and impeller, provides a sealing surface against the transmission input shaft, and compensates for charge pressure-induced deflections. This multi-functionality improves torque transmission stability without requiring separate components for each function, thus avoiding excessive complexity.
3Reliability
If the sealing surface is engaged with the transmission input shaft, then the pressure balance is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The cover compensator includes a compensator plate that can deflect beforehand under charge pressure, cushioning the pressure-induced stresses before they reach the sealing surface. This pre-compliance design maintains pressure balance while reducing the precision requirements for the sealing surface engagement with the transmission input shaft.
Solution Approach 2:
The cover compensator changes the pressure distribution parameters by providing a compliant sealing surface that can deflect under charge pressure. This parameter change allows the sealing surface to maintain engagement with the transmission input shaft while accommodating pressure variations, thereby maintaining pressure balance without requiring extremely high manufacturing precision.
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 cover compensator effectively minimizes deflection and maintains pressure balance, ensuring consistent torque transmission and reducing mechanical losses by providing a stable interface between the front cover and impeller, enhancing clutch control and cooling efficiency.
Implementation Method 1
The cover compensator has an inner surface configured to seal against an input shaft of a transmission
Implementation Method 2
The cover compensator has an aperture to fluidly couple fluid chambers located on either axial side of the cover compensator
Data Source
AI summary
A torque converter includes a front cover configured to receive an input torque, and an impeller having an outer shell coupled to the front cover. A clutch is selectively engageable by a piston. A cover compensator is located axially between the front cover and the piston. The cover compensator is configured to reduce deflection of the front cover in the event of high pressures when changing gears in the transmission. The cover compensator has a radially-innermost sealing surface configured to engage and seal with a transmission input shaft. The cover compensator may also has an aperture to fluidly couple fluid chambers located on either axial side of the cover compensator. This can allow fluid to be forced through the clutch to continuously lubricate the clutch.