Torque Converter Leaf Spring Buckling Prevention
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Solution Overview
Problem
Leaf springs in torque converters are prone to buckling under compression forces during engine braking in vehicles with strong engine resistance, leading to permanent deformation and potential failure.
Innovation Solution
A buckling prevention device featuring a retainer rivet with a head that connects the leaf spring to a drive plate, allowing axial movement but engaging to prevent buckling by transferring torque directly when high compression forces are detected, using a gap between the rivet and the drive plate that closes to act as a stop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If leaf springs are used to transfer torque while enabling axial movement, then the torque converter can accommodate piston movement, but the leaf springs are prone to buckling under compression forces during engine braking
Solution Approach 1:
The connection between the leaf spring and drive plate is segmented into two states: a gap exists during normal operation allowing axial movement, but the gap closes under high compression to engage a stop feature. This segmentation allows the system to adapt between movement and buckling prevention modes.
Solution Approach 2:
The retainer rivet is pre-positioned with its stop feature aligned to engage with the drive plate when the gap closes. This preliminary positioning ensures that when compression forces exceed the threshold, the buckling prevention mechanism is immediately activated without delay.
2Strength
If the leaf springs are made thin and plate-like for good tensile strength, then they can flex to enable piston movement, but they become vulnerable to buckling under compression forces
Solution Approach 1:
The leaf spring maintains thin plate-like geometry for good tensile strength and flexibility, but the system incorporates a local structural feature (the retainer rivet stop mechanism) that provides buckling resistance only when needed. This local quality addition prevents buckling without compromising the overall thin design.
Solution Approach 2:
The retainer rivet acts as an intermediary element between the leaf spring and drive plate. It includes a stop feature that engages with the drive plate to prevent buckling, while the gap between the rivet and drive plate allows normal axial movement. This intermediary structure provides buckling prevention without requiring the leaf spring itself to be thicker.
3Reliability
If a rigid connection is made between the leaf spring and drive plate to prevent buckling, then buckling resistance improves, but axial movement capability is compromised
Solution Approach 1:
The connection between the retainer rivet and drive plate is dynamic rather than static. The gap between the rivet and drive plate allows axial movement during normal operation, but when compression forces increase, the gap closes and the rivet engages with the drive plate to prevent buckling. This dynamic behavior allows the system to adapt between movement and stability modes.
Solution Approach 2:
The retainer rivet assembly automatically responds to compression forces by closing the gap and engaging the stop feature when buckling is detected. This self-service mechanism activates buckling prevention only when needed, without requiring external control or compromising normal axial movement capability.
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
Prevents leaf spring buckling by limiting axial movement and transferring torque directly, enhancing the longevity of the torque converter components without compromising performance or causing rattling issues.
Implementation Method 1
The leaf springs enable the transfer of torque through the leaf springs to the piston while also being able to flex to enable the piston to move axially
Implementation Method 2
the connection member is operatively arranged to close the gap and engage with the first member when the spring is experiencing an overly high compression force for preventing the leaf spring from buckling
Data Source
AI summary
A buckling prevention device including a first rotational element, a second rotational element, a leaf spring arranged for transferring torque between the first and second rotational elements while enabling relative axial movement between the first rotational element and the second rotational element, a connection member fixedly connecting the leaf spring to the second rotational element, wherein the connection member extends axially through a hole in the first rotational element, wherein a gap is formed between the connection member and an edge of the hole when the leaf spring is not experiencing an overly high compression force, and wherein the connection member is operatively arranged to close the gap and engage with the first member when the spring is experiencing an overly high compression force for preventing the leaf spring from buckling and at least partially transferring the torque directly between the first and second rotational elements.