Torque Converter Mechanical Lock for Industrial Start-Up
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Solution Overview
Problem
Large rotating industrial equipment with high inertia and operating loads often require powerful starter motors to reach operating speed, which are expensive and complex due to the need for variable frequency electrical supply and control systems.
Innovation Solution
A system utilizing a torque converter and a shiftable mechanical lock, such as a synchro self-shifting clutch, to transmit torque from a rotational driver like a gas turbine to the equipment, allowing for adjustable operation between freewheel and torque-transmitting modes to facilitate start-up without a large starter motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a powerful starter motor is used to accelerate large rotating industrial equipment from zero to full operating speed, then the equipment can reach operating speed, but the system becomes very expensive and complex due to variable frequency electrical supply and control systems
Solution Approach 1:
The patent replaces the electrical starter motor system with a mechanical torque converter and gear mechanism system. The torque converter uses fluid dynamics to transmit and multiply torque mechanically, eliminating the need for complex variable frequency electrical supply and control systems while still achieving the required acceleration from zero to full operating speed.
Solution Approach 2:
The patent introduces a torque converter as an intermediary device between the driver and the rotating equipment. This torque converter serves as a mechanical mediator that provides torque multiplication during start-up, allowing the system to accelerate large inertia loads without requiring a powerful starter motor with complex electrical controls.
2Device complexity
If a torque converter is used to transmit torque from the driver to the rotating equipment, then the start-up can be achieved without a large starter motor, but rotational slippage occurs during torque transmission
Solution Approach 1:
The patent employs a shiftable mechanical lock that can dynamically change the operational mode of the torque converter. During start-up, the lock is disengaged allowing the torque converter to operate in torque-transmitting mode with some slippage. Once operating speed is reached, the lock engages to create a rigid mechanical connection, eliminating slippage during normal operation and optimizing efficiency.
3Loss of energy
If a shiftable mechanical lock is used to synchronize speeds and transmit torque, then torque transmission efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent employs a synchro self-shifting clutch mechanism that automatically engages and disengages based on speed synchronization. The mechanism self-regulates by comparing the speeds of the driver and load-side elements, and when speeds are synchronized, the clutch automatically engages to transmit torque rigidly, eliminating the need for external control systems and minimizing added complexity.
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
Enables the start-up of large rotating industrial equipment without the need for a powerful starter motor, reducing costs and complexity by using a torque converter and mechanical lock to synchronize and transmit torque efficiently, thereby minimizing rotational slippage and optimizing power usage.
Implementation Method 1
using a torque converter to transmit torque from a rotational driver to the rotating industrial equipment, said torque converter being adjustable between a freewheel mode and a torque-transmitting mode
Implementation Method 2
using at least one gear mechanism to substantially synchronize the speeds of a first drive-side element and a first load-side element, the first drive-side and load-side elements having a shiftable mechanical lock coupled therebetween, said shiftable mechanical lock being a synchro self-shifting clutch
Data Source
Figure 1~2
Figure 3
Figure 4~5c
AI summary
A system that employs a torque converter and a shiftable mechanical lock to start up rotating industrial equipment. A gear mechanism is employed to account for rotational slippage inherent in the torque converter. The torque converter and gear mechanism are used during start-up to increase the speed of the rotating industrial equipment. When the speed of the rotating industrial equipment is substantially synchronized with the speed of the driver, the mechanical lock is engaged.