Torque Converter Damper Assembly for Compact Spring Packaging
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Solution Overview
Problem
The limited spacing within torque converters poses challenges in packaging all necessary components, particularly in manufacturing components to meet reduced tolerances, which affects the design and functionality of the damper assembly.
Innovation Solution
The torque converter design includes a damper assembly with an inner and outer spring assembly, supported by cover plates, where the lower cover plate features a chamfer to retain the outer spring assembly and an intermediate flange to transfer torque to the inner spring assembly when thresholds are exceeded, allowing for more compact packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the torque converter envelope spacing is reduced to improve packaging, then the volume and area of components are reduced, but manufacturing precision deteriorates due to reduced tolerances
Solution Approach 1:
The damper assembly is segmented into multiple functional components including an outer spring assembly, an inner spring assembly, a lower cover plate with chamfer, and an intermediate flange. This segmentation allows each component to be optimized independently for compact packaging while maintaining manufacturing feasibility through standardized tolerances on individual parts rather than the entire assembly.
2Volume of moving object
If the damper assembly is compacted to fit limited spacing, then the volume of the damper assembly is reduced, but device complexity increases due to multiple spring assemblies and cover plates
Solution Approach 1:
The inner spring assembly is nested within the outer spring assembly, with the lower cover plate containing the chamfer that retains the outer spring assembly. This nested configuration allows both spring assemblies to occupy overlapping spatial volumes, significantly reducing the overall envelope size of the damper assembly while maintaining the functional complexity of dual spring systems for torque transfer and damping.
Solution Approach 2:
The lower cover plate serves multiple functions: it supports the inner spring assembly, provides the chamfer to retain the outer spring assembly, and connects to the intermediate flange for torque transfer. The intermediate flange also serves dual purposes by transferring torque between the spring assemblies and providing structural support. This multi-functionality reduces the number of separate components needed, simplifying the overall structure while maintaining compact dimensions.
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
This configuration enables the packaging of the damper assembly in smaller envelopes while maintaining effective torque transfer, enhancing the overall efficiency and functionality of the torque converter.
Implementation Method 1
a damper assembly disposed axially between the front cover and the turbine shell and engageable with the clutch plate. The damper assembly includes an inner spring assembly, an outer spring assembly arranged radially outside of the inner spring assembly
Data Source
AI summary
A torque converter includes a front cover arranged to receive a torque and a lock-up clutch engaged with the front cover. The torque converter further includes a damper assembly engageable with the lock-up clutch. The damper assembly includes an inner spring assembly, an outer spring assembly arranged radially outside of the inner spring assembly, and a lower cover plate supporting the inner spring assembly. The lower cover plat includes a chamfer configured to retain the outer spring assembly in a spring window.