Torque Converter Embossed Cover Radial Positioning
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Solution Overview
Problem
In prior art torque converters, the radial positioning of the carrier plate with respect to the cover is difficult to achieve accurately due to sliding issues before welding, and the welds are susceptible to failure under shearing forces when the lock-up clutch is activated, leading to potential mechanical weakness.
Innovation Solution
The torque converter incorporates an embossed cover with a circumferential indentation and a protrusion on the carrier plate, which fixes the radial position of the plate during welding, providing structural support against shearing forces and ensuring accurate positioning through interlocking mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the carrier plate is welded to the cover without an interlocking structure, then the manufacturing process is simple, but the radial positioning accuracy is poor and the welds are susceptible to shearing forces
Solution Approach 1:
The protrusion on the carrier plate fits into a recess on the cover, creating a nested interlocking structure. This nesting arrangement provides precise radial positioning while distributing shear forces, eliminating the need for additional positioning fixtures or complex alignment procedures during welding.
Solution Approach 2:
The solution adds a radial dimension to the positioning mechanism by incorporating protrusions and recesses that extend in the radial direction. This radial interlocking feature works in conjunction with the axial welding direction to prevent both radial displacement and shear failure, effectively addressing positioning accuracy without complicating the welding process.
2Strength
If only welds are used to hold the carrier plate to the cover, then the structure is simple, but the welds fail under shearing forces when the clutch is closed
Solution Approach 1:
The protrusion-recess interlocking structure is pre-formed on the carrier plate and cover before welding takes place. This preliminary mechanical interlocking prepares the joint to resist shear forces, allowing the welds to primarily provide axial bonding strength rather than having to withstand radial shear loads alone.
Solution Approach 2:
The solution merges two functions into a single structural feature: the protrusion-recess interface simultaneously provides radial positioning accuracy and shear force resistance. This combined function eliminates the need for separate positioning elements and strengthens the weld joint without adding significant structural complexity.
Data Source
AI summary
A torque converter, including: an axis of rotation; a cover arranged to receive torque from an engine and including a first indentation; an impeller shell fixedly secured to the cover; at least one impeller blade fixedly secured to the impeller shell; a turbine including a turbine shell and at least one turbine blade fixedly secured to the turbine shell; and a lock-up clutch including a first carrier plate fixedly secured to the cover and including a first protrusion disposed in the first indentation and a clutch plate non-rotatably connected to the first carrier plate.