Torque Converter Lug Reaction Plate for Simplified Assembly
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Solution Overview
Problem
Torque converter assemblies face complexities in connections between components, leading to high labor costs and assembly time due to the need for separate reaction and connection plates.
Innovation Solution
A multi-functional plate with flanges and chamfered surfaces for welding connections, acting as both a reaction plate and connection lug, simplifies assembly by integrating functions and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate reaction plate and connection plate are used, then functional requirements are met, but assembly complexity and labor costs increase
Solution Approach 1:
The patent combines the reaction plate and connection plate into a single integrated plate component. This merged component includes a reaction plate portion that engages with the clutch plate assembly and a connection plate portion with lug features for connecting to the flex plate. By integrating these two previously separate components into one, the patent reduces assembly complexity and the number of parts while maintaining all necessary functional requirements for both clutch engagement and drive connection.
Solution Approach 2:
The integrated plate serves multiple functions simultaneously: it acts as a reaction plate for the clutch plate assembly, provides connection lugs for the flex plate, and includes flow holes for fluid communication. This multi-functional design eliminates the need for separate dedicated components for each function, thereby reducing overall device complexity while ensuring all functional requirements are met.
2Productivity
If multiple separate components are used, then specific functions are fulfilled, but assembly time and labor costs increase
Solution Approach 1:
The patent merges the reaction plate and connection plate into a single integrated component, reducing the number of parts that need to be handled and assembled. This integration directly improves productivity by reducing assembly time and labor costs, while the design maintains ease of operation through features like pre-positioned lug openings and flow holes that simplify the assembly process.
3Reliability
If separate reaction plate and connection plate are used, then functional requirements are met, but number of components increases
Solution Approach 1:
The patent integrates the reaction plate and connection plate into a single component, reducing the total number of parts in the torque converter assembly. This merged plate includes both the reaction plate portion for clutch engagement and the connection plate portion with lug features, thereby decreasing component quantity while maintaining all necessary functional requirements.
Solution Approach 2:
The integrated plate performs multiple functions that previously required separate components: it provides the reaction surface for the clutch plate assembly, includes lug openings for flex plate connection, and incorporates flow holes for fluid communication. This multi-functionality allows a single component to replace what were previously two or more separate parts.
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 integrated plate design enhances manufacturing and assembly efficiencies by streamlining the assembly process and reducing the number of components, thereby lowering labor costs and assembly time.
Implementation Method 1
A connection, such as a welded connection, can be provided at an interface between the plate and the front cover. Another connection, which can also include a welded connection, is provided at an interface between the plate and the pump cover.
Data Source
AI summary
A torque converter assembly is disclosed that includes a front cover, a clutch plate assembly, a pump cover, and a plate including a base body extending in an axial direction with a first flange on a first end and a second flange on a second end. The first flange can define a friction face configured to engage with a corresponding surface of the clutch plate assembly, and the second flange can define at least one opening configured to receive a fastening element. In one aspect, the plate functions or serves as a reaction plate for the clutch assembly, and also serves as a connection or lug for a flex plate or other component.