Torque Converter Cover Assembly with Elastic Preloading

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Solution Overview

Problem

Existing torque converter cover assemblies face challenges in managing cyclic loading at the connection between the drive plate and the front cover, particularly in ensuring secure attachment while minimizing stress concentrations.

Innovation Solution

A cover assembly for a torque converter featuring a drive plate with elastic preloading elements, such as tabs formed within the drive plate and extending radially, which are compressed against the front cover, either through riveting or welding, to limit cyclic loading primarily to compression.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the drive plate is rigidly connected to the front cover, then the connection strength is improved, but the cyclic loading stress concentration increases

Engineering Contradiction:

Improveconnection strengthVSAvoidcyclic loading stress concentration

Core Design Contradiction:

StrengthVSStress or pressure

Solution Approach 1:

The drive plate incorporates elastic preloading elements that change the mechanical parameters of the connection by introducing controlled elasticity. This allows the connection to maintain strength while accommodating cyclic loading through elastic deformation, thereby reducing stress concentration at rigid connection points.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The elastic preloading elements are designed to compress beforehand under preload, creating a cushioning effect that absorbs cyclic loading variations. This pre-compression ensures that during operation, the connection experiences reduced stress fluctuations, preventing stress concentration and fatigue failure.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If elastic preloading elements are added to the drive plate, then cyclic loading mitigation is improved, but the device complexity increases

Engineering Contradiction:

Improvecyclic loading mitigationVSAvoiddrive plate structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The elastic preloading elements are integrated directly into the drive plate structure, merging the function of cyclic loading mitigation with the existing drive plate components. This integration approach reduces overall device complexity by eliminating separate cushioning components and simplifying the assembly process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The material properties and geometric parameters of the drive plate are modified to incorporate elastic preloading elements. By changing parameters such as plate thickness, material elasticity, and element geometry, the drive plate gains cyclic loading mitigation capability without requiring additional complex mechanisms.

Inventive Principle:

Principle #35Parameter changes

3Force

If the tabs are bent toward the front cover, then the preloading force is improved, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvepreloading forceVSAvoidtab bending precision

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The tabs are pre-formed with bend lines and predetermined geometry during manufacturing, allowing for controlled bending toward the front cover. This preliminary preparation ensures that the tabs achieve the correct preloading force while maintaining consistent manufacturing precision through standardized forming processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The tab geometry parameters are optimized to achieve the desired preloading force with moderate bending angles. By adjusting parameters such as tab length, width, and bend radius, the design balances preloading force generation with manufacturing feasibility, reducing precision requirements while maintaining effective preloading.

Inventive Principle:

Principle #35Parameter changes

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 elastic preloading elements effectively distribute and mitigate cyclic loading, enhancing the structural integrity and reliability of the connection between the drive plate and the front cover, thereby reducing the risk of failure at the attachment points.

Implementation Method 1

The elastic preloading element may limit the cyclic loading at the connection between the drive plate and the front cover

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10274064B2Cover assembly for a torque converter including drive plate having elastic preloading element

Publication Date: 2019.04.30 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

A cover assembly for a torque converter includes a front cover and a drive plate connected to an outer surface of the front cover for coupling to the front cover to an engine crankshaft. The drive plate includes elastic preloading elements pressing against the outer surface of the front cover. A method of forming a cover assembly for a torque converter includes fixing a drive plate to an outer surface of a front cover of the torque converter such that elastic preloading elements of the drive plate press against the outer surface and are compressed.