Torque Converter Centering Flange Sub-Assembly Welding
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Solution Overview
Problem
Existing centering flanges in torque converters face challenges in maintaining a durable connection and efficient fluid pressure path during the manufacturing process, leading to potential gaps and reduced performance.
Innovation Solution
A flange design comprising a first and second sub-assembly with strategically placed holes and welds, allowing for a defined gap between the sub-assemblies to facilitate fluid pressure paths from the transmission input shaft to the piston, and a manufacturing method involving hole formation and welding to ensure a secure and efficient fluid pressure path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the centering flange is welded during manufacturing, then the connection between the centering flange and cover is strengthened, but gaps may form between sub-assemblies reducing fluid pressure path efficiency
Solution Approach 1:
The centering flange is divided into first and second sub-assemblies that are joined through welding. This segmentation allows each sub-assembly to be manufactured and positioned separately, then permanently joined to maintain both structural strength and proper fluid pressure path alignment throughout operation.
Solution Approach 2:
Holes are formed in the first sub-assembly before welding to the second sub-assembly. This preliminary action ensures that the fluid pressure path geometry is established prior to joining, preventing misalignment that could occur if holes were formed after welding.
2Productivity
If holes are formed to facilitate fluid pressure path, then the piston application and release efficiency is improved, but the structural integrity of the flange may be compromised
Solution Approach 1:
The flange is segmented into sub-assemblies where holes are formed in the first sub-assembly before joining. This allows the fluid pressure path features to be created in a controlled manner without compromising the overall structural integrity of the complete flange assembly.
Solution Approach 2:
The first and second sub-assemblies are merged through welding to form a complete centering flange that maintains both the fluid pressure path holes and sufficient structural integrity. The combination of sub-assemblies distributes structural loads while preserving the functional holes.
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 design enhances the durability and efficiency of the fluid pressure path, reducing reaction forces and improving the performance of the torque converter by maintaining a consistent and effective fluid flow during both piston application and release.
Implementation Method 1
a second sub-assembly that includes one or more welds that join a first contact-side of the second sub-assembly to the first sub-assembly
Implementation Method 2
the first and second hole are configured to facilitate movement of a first pressure path from a transmission input shaft to a piston
Data Source
AI summary
A flange for a torque converter, comprising a first sub-assembly that includes a first hole and second hole located along the first sub-assembly and wherein the first and second hole are configured to facilitate movement of a first pressure path from a transmission input shaft to a piston. The flange for the torque converter also includes a second sub-assembly that includes one or more welds that join a first contact-side of the second sub-assembly to the first sub-assembly, wherein a gap is defined between an area where the second sub-assembly is joined to the first sub-assembly.