Torque Converter Flexible Axial Contact Surface
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrodynamic torque converters face challenges in maintaining precise axial contact between the pump and turbine wheels, leading to potential slip, bearing issues, and fatigue due to axial offset or wobbling movements, which affect the quiet, low-loss, and comfortable operation.
Innovation Solution
A hydrodynamic torque converter with a flexible axial contact surface designed to engage closely under axial pressure, formed by a circumferentially folded metal sheet, which can be elastically deformed to improve the engagement and reduce slip between the pump and turbine wheels, incorporating a lock-up clutch for smoother operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rigid contact surfaces are used in the lock-up clutch, then manufacturing precision can be maintained, but axial offset and wobbling movements occur leading to bearing issues and fatigue
Solution Approach 1:
The patent applies a flexible contact surface made from a metal sheet that is folded circumferentially to form a lock-up clutch. This flexible membrane allows the contact surface to adapt to axial offsets and wobbling movements, ensuring continuous contact between the pump wheel and turbine wheel while eliminating bearing issues and fatigue problems associated with rigid contact surfaces.
2Adaptability or versatility
If the metal sheet is folded with a small fold angle, then flexibility is increased, but the structural strength decreases
Solution Approach 1:
The patent applies local quality by varying the wall thickness of the metal sheet along its circumference. The metal sheet has a non-uniform cross-section with different wall thicknesses in different regions, allowing areas requiring flexibility to be thinner while maintaining structural strength in load-bearing regions. This gradient thickness distribution optimizes both flexibility and strength simultaneously.
3Loss of energy
If the contact surfaces are pressed axially against each other, then slip is reduced, but axial offset and wobbling movements occur
Solution Approach 1:
The patent applies dynamics by designing the lock-up clutch with a flexible contact surface that can dynamically adapt its shape under axial pressure. The flexible membrane allows the contact surface to deform and accommodate axial offsets and wobbling movements while maintaining continuous contact, thereby reducing slip and energy loss without compromising regulating behavior or reliability.
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 flexible contact surface enhances the bearing behavior, regulating capabilities, and reduces axial offset or wobbling movements, ensuring a more efficient and controlled engagement, thereby minimizing slip and improving the overall performance of the torque converter.
Implementation Method 1
The fold angle is less than 180° so that the unloaded fold is open. The portion of the metal sheet which forms one of the contact surfaces can thus be elastically deformed in an improved manner when the pump wheel and the turbine wheel are pressed axially against one another.
Implementation Method 2
a first axial contact surface is formed on the pump wheel and a second axial contact surface is formed on the turbine wheel, so that a frictional connection between the pump wheel and the turbine wheel can be produced when the pump wheel and the turbine wheel are pressed axially against one another
Data Source
AI summary
A hydrodynamic torque converter comprising a pump wheel and a turbine wheel mounted to be rotatable about an axis of rotation is disclosed. A fluid in a region between the pump wheel and the turbine wheel is provided wherein a first axial contact surface is formed on the pump wheel and a second axial contact surface is formed on the turbine wheel. A frictional connection between the pump wheel and the turbine wheel can be produced when the pump wheel and the turbine wheel are pressed axially against one another. Moreover, one of the contact surfaces is configured to be flexible in order to lie against the other contact surface under an axial pressure load.