Torque Converter Stud Weld Structure for Fatigue-Resistant Joints
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Solution Overview
Problem
Stud welds in torque converters often fail due to fatigue induced by alternating engine forces, leading to inefficient weld quality and potential joint failure.
Innovation Solution
A stud design with an annular projection on the head that penetrates the torque converter cover, allowing direct contact and securement of the flex plate, eliminating the need for additional materials and reducing the complexity of welding, thereby enhancing weld quality and reducing fatigue-induced forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stud welds are used to connect the flex plate to the torque converter cover, then the joint can be formed, but the weld quality is insufficient and fatigue failure occurs due to alternating engine forces
Solution Approach 1:
The stud head is segmented into multiple functional zones: a grounding area that contacts the torque converter cover, a shaft, and a pad area. This segmentation allows the welding process to concentrate on the grounding area, creating a stronger, more reliable weld joint while distributing mechanical loads across different zones of the stud structure
Solution Approach 2:
The stud head features a localized grounding area with enhanced properties for welding, distinguished from the rest of the stud structure. This local quality enhancement ensures optimal weld formation at the critical interface with the torque converter cover, while maintaining overall structural integrity through the shaft and pad portions
2Ease of manufacture
If traditional stud designs with separate pads are used, then the components can be connected, but the device complexity increases and manufacturing costs increase
Solution Approach 1:
The stud design merges the pad function directly into the stud head structure, eliminating the need for a separate pad component. The stud head itself serves as both the welding substrate and the load-distributing pad, reducing the total number of parts and simplifying the assembly process while maintaining structural functionality
Solution Approach 2:
The stud head is designed to perform multiple functions: it provides a grounding area for welding to the torque converter cover, acts as a structural shaft for connection, and serves as a pad for load distribution. This multi-functionality reduces the need for separate components and simplifies the overall device structure
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 stud design improves weld quality by increasing the weld-grounding area ratio, reduces manufacturing costs, and eliminates the need for a floating pad, resulting in a more reliable and durable connection that resists fatigue and bending moments.
Implementation Method 1
a stud including a head and an end with a shaft therebetween, wherein the head includes an annular projection penetrating a flex plate in contact with the torque converter and the front surface of the cover
Data Source
AI summary
A torque converter in a vehicle includes a cover for the torque converter, wherein the cover includes a front surface and a back surface and a stud including a head and an end with a shaft therebetween passing through an opening of a flex plate, wherein the head includes a top surface and a bottom surface, wherein the top surface include an annular projection penetrating the front surface of the cover and the bottom surface is adjacent the shaft.