Torque Converter Stator Thrust Bearing Hydrodynamic Film
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Solution Overview
Problem
Conventional torque converters experience significant thrust loads and metal-on-metal contact between stators and impellers, leading to inefficiencies and potential damage, especially in applications with axially movable turbines.
Innovation Solution
The implementation of a tapered land thrust bearing with a hydrodynamic film between the stator and impeller, utilizing a ramped or tapered surface combined with a short flat surface to prevent metal-on-metal contact, maintaining a hydrodynamic film that reduces thrust loads by up to 50% and matches calculated thrust values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional torque converters operate without a dedicated thrust bearing, then the structure remains simple, but metal-on-metal contact occurs between stator and impeller causing high thrust loads and potential damage
Solution Approach 1:
A thrust bearing is introduced as an intermediary component between the stator and impeller to prevent direct metal-on-metal contact. The bearing surface with its hydrodynamic film acts as a mediator that separates the two rotating components, eliminating harmful contact while managing thrust loads.
Solution Approach 2:
The thrust bearing utilizes hydraulic principles by generating a hydrodynamic fluid film between the bearing surface and the opposing component. This fluid film replaces direct metal contact with fluid-based separation, reducing friction and preventing wear through hydraulic cushioning.
2Force
If a thrust bearing with bearing surface is added to maintain hydrodynamic film, then thrust loads are reduced by up to 50%, but the device complexity increases
Solution Approach 1:
The thrust bearing replaces direct mechanical contact between metal surfaces with a hydrodynamic fluid film system. This substitution transforms the load-bearing mechanism from solid-to-solid contact to fluid-based support, significantly reducing thrust loads while managing the complexity through integrated design.
3Productivity
If tapered land thrust bearing is implemented, then operational efficiency is enhanced through reduced metal contact, but manufacturing complexity increases
Solution Approach 1:
The thrust bearing features a bearing surface with specific local geometric properties (tapered land configuration) optimized for hydrodynamic film generation. This localized quality enhancement at the contact interface improves operational efficiency by ensuring proper fluid film formation while keeping the rest of the component design relatively simple.
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 hydrodynamic film significantly reduces thrust loads on the bearing surface, minimizing metal contact and enhancing operational efficiency, while also potentially reducing the axial dimension of the torque converter.
Implementation Method 1
a bearing surface arranged for maintaining a hydrodynamic film thereon in a region of the first fluid flow or the second fluid flow during operation of the torque converter
Data Source
AI summary
A torque converter is provided. The torque converter includes an impeller including an impeller shell, a turbine including a turbine shell and a stator axially between the turbine and the impeller. A first fluid flow is generated between the impeller and the stator and a second fluid flow is generated between the turbine and the stator. The torque converter further includes a thrust bearing axially between the impeller and the stator or axially between the turbine and the stator. The thrust bearing includes a bearing surface arranged for maintaining a hydrodynamic film thereon in a region of the first fluid flow or the second fluid flow during operation of the torque converter. A method of forming a torque converter is also provided.