Torque Converter Shell Blade Tab Alignment
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Solution Overview
Problem
Conventional methods for manufacturing torque converter shells with blade tabs result in misalignment and deformation, leading to poor blade attachment and increased waste, as well as issues with brazing paste leakage and furnace malfunctions due to precise control requirements.
Innovation Solution
The use of radial indents and slots on the torque converter shells, where blade tabs are affixed to indents and bent over the shell surface, and slots are formed in concentric rows to reduce deformation and improve alignment, allowing for a more reliable and efficient attachment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to manufacture torque converter shells with blade tabs, then production can proceed with standard processes, but blade tab misalignment and deformation occur leading to poor blade attachment and increased waste
Solution Approach 1:
The patent applies preliminary action by forming indents and slots in the shell before the forming process, and pre-attaching blade tabs to the shell prior to final assembly. This sequence ensures that the attachment features are established when the shell is still in a more stable, less deformed state, preventing misalignment that would occur if attachment happened after shell deformation.
Solution Approach 2:
The patent segments the blade attachment system into multiple independent components: indents formed in the shell, slots cut after forming, and separate blade tabs that are attached to the shell. This segmentation allows each component to be optimized and controlled independently, with the blade tabs serving as separate elements that can be precisely positioned and attached without being affected by shell deformation.
2Manufacturing precision
If precise control is maintained during manufacturing to prevent deformation, then blade attachment quality improves, but manufacturing complexity and difficulty increase
Solution Approach 1:
The patent reduces manufacturing complexity by performing preliminary actions at optimal times: forming indents in the blank before shell forming (when the material is stable), cutting slots after shell forming (when the shell has achieved its final shape), and attaching blade tabs in between these steps. This staged approach simplifies each individual operation compared to attempting to control all variables simultaneously in a single complex process.
Solution Approach 2:
The patent segments the manufacturing process into distinct, manageable stages: indent formation, shell forming, slot cutting, and blade tab attachment. Each stage can be performed with standard equipment and processes, avoiding the need for a single highly complex integrated process. The segmentation allows each operation to be optimized independently with conventional machinery.
3Reliability
If blade tabs are securely attached to shells, then torque converter reliability improves, but manufacturing time and process steps increase
Solution Approach 1:
The patent applies preliminary action by attaching blade tabs to the shell before final assembly, allowing the attachment process to be performed when access is easier and positioning is more accurate. This preliminary attachment ensures reliable bonding while enabling parallel processing of multiple components, improving overall manufacturing efficiency compared to attaching blades after assembly when access would be more difficult.
4Strength
If brazing paste is applied for blade attachment, then strong bonding is achieved, but paste leakage occurs causing furnace malfunctions
Solution Approach 1:
The patent applies preliminary action by attaching blade tabs to the shell before inserting blades into the slots. This sequence allows the brazing paste to be contained and controlled during the tab attachment process, preventing leakage into the furnace. The blades are then inserted into the already-attached tabs, completing the assembly without requiring additional brazing operations that could cause paste leakage.
Data Source
AI summary
A blade with first and second blade tabs extending outwardly from an edge of the blade; and a shell with a first indent and a first slot. The first blade tab is arranged to engage the first indent and the second blade tab is arranged to engage the first slot. In one embodiment, the first indent is arranged radially inward on the shell relative to the first slot. In one embodiment, the first blade tab is affixed to the first indent. In one embodiment, the second blade tab is bent over an outside surface of the turbine shell. In one embodiment, the shell includes a second indent and the blade includes a third blade tab extending outwardly from the edge and at least partially disposed in the second indent. A method of manufacturing a pump or turbine shell for a torque converter.